Page 1 450 Rally Maintenance manuals First Edition (February 2023) This maintenance manual is copyrighted by TIBET NEW SUMMIT MOTORCYCLE CO.,LTD. The contents and pictures of this maintenance manual are for reference only, please refer to the actual. English version...
Page 2 This motorcycle manual provides the reader with a detailed introduction to the basic structure, operating principles, disassembly and overhaul, and troubleshooting methods of the 450 Rally motorcycle. It also introduces the technical specifications, performance parameters and maintenance adjustment data of this model. It is hoped that this manual will provide technical support and guidance to the users and after-sales service personnel of Kaiyue motorcycles.
Page 3 Contents Introduction Chapter 1 Overview ....................... 1 Chapter 2 Basic information ..................3 Chapter 3 Regular maintenance and adjustment ..........28 Chapter 4 Frame, body trim, exhaust system ............72 Chapter 5 EFI ........................89 Chapter 6 Fuel System ....................124 Chapter 7 Cooling System ..................
Page 4 Chapter 1 How to use this manual This manual describes the maintenance procedures for the 450 Rally. Chapter 2 and 3 apply to the entire motorcycle. Chapter 4 describes the procedures for removing/installing components that may be used to perform the services described in the following sections. Chapter 3-- Chapter 19 describe the motorcycle's components, grouped by location.
Page 5 Symbol The symbols used in this manual represent specific repair procedures. If additional information related to these symbols is required, it will be explained in detail in the text without using these symbols Replace parts with new parts before assembly Use recommended oils unless otherwise explanation Use molybdenum oil solution (oil and molybdenum grease mixed in a ratio of 1:1)
Page 6: Table Of Contents
Basic information 1 Maintenance rules ....................4 2 Model identification ....................5 3 Basic information ....................6 4 Torque value - engine part ................13 5 Torque value - body part .................. 15 6 Lubrication and sealing point - Engine part..........26 7 Lubrication and sealing point - body part...........
Page 7: Maintenance Rules
Maintenance rules Please use genuine or KOVE recommended parts and lubricants or their equivalents for the KUVE. Parts that do not meet KOVE's design specifications may damage the motorcycle. Use special tools designed for this product to avoid damage and incorrect assembly.
Page 8: Model Identification
Model identification factory edition-⑴ regular edition-⑵ ⑴ ⑵ English version...
Page 9: Basic Information
Basic information items specification Total lenght 2190 mm Total Width 830 mm Total height 1487 mm Axle distance 1475 mm Load free seat height 960 mm Size No load pedal height 360 mm No load ground clearance 300 mm Dry weight 155 kg Permissible maximum front axle load 150 kg...
Page 10 items specification The Fuel Type Bosch EFI Supply Throttle valve hole 46mm System Clutch system Wet multichip type Clutch operating Cable operation system Normal mesh two-stage Gearbox transmission, 6-speed Primary drive 2.286（69/34） Final drive 3.769 Drive system 2.357（43/15） 1.824 (46/14) 1.474 (40/19) Gear Ratio 1.181(32/20)
Page 11 Start motor brush length items specification hrottle body identification number 450R Fuel pressure at idle 380Kpa±10kpa Fuel pump flow (12V, 380kpa) ≥30L/h Type Bosch EFI/ Fuel oil supply system Throttle valve hole 46mm cooling system items specification Cooling capacity radiator tank 1.2 L The radiator cap releases pressure 108-133 kPa...
Page 12 Engine cylinder head/valve specification Measurement units：mm items Standard value limit value Intake φ5.472-φ5.487 φ5.46 Outside diameter of valve stem Exhaust φ5.46-φ5.475 φ5.44 Intake φ5.505-φ5.515 φ5.535 Valve tube valve diameter Exhaust φ5.505-φ5.515 φ5.535 Intake 0.018-0.043 0.07 Valve stem and tube clearance Exhaust 0.03-0.055 0.08...
Page 13 Shift fork/shift fork shaft/crankshaft/balance shaft specifications Measurement units：mm items Standard value limit value Internal diameter of the right fork of the φ12.016-φ12.043 φ12.045 secondary shaft / Internal diameter of the left fork of the secondary shaft Shift fork φ12.016-φ12.043 φ12.045 Spindle fork inner diameter 4.8-4.9 Jaw thickness...
Page 14 Front wheel/suspension/steering specifications items Standard value limit value Vacuum tire（regular 200kPa(2.0kgf/cm³，29 psi) Tire edition） Pressure Inner Tire（regular edition） 100kPa(1.0kgf/cm³，15 psi) Shaft Runout ≤ 0.8 radial direction ≤ 0.8 Rim Runout end face ≤ 0.8 Wheel dynamic balance Max 60g Free spring length/regular 475 mm edition/factory edition Recommended shock...
Page 15 Hydraulic brake specification Measurement units：mm items Standard value limit value DOT 4 Specify brake fluid To groove Brake disc wear indicator 4.0-4.01 Brake disc thickness Front 0.15 Brake disc warped Brakes 11.000-11.050 11.060 Main piston outer diameter Caliper piston cylinder outside 27.000-27.050 27.06 diameter...
Page 16: Torque Value - Engine Part
Torque value - engine part Listed below are the specifications apply to the specified torque fasteners. Other should · tighten to the above standard torque values. The standard torque value · Type of fastener Torque N.m Type of fastener Torque N.m 5mm screw bolt and nut 5mm bolt 6mm screw bolt and nut...
Page 17 Clutch and shift mechanism torque Diameter of items Torque N.m Note screw mm Clutch fastening nut 80-90 Thread fastening glue Clutch spring bolt 8-10 Drive gear fastening nut 115-125 Thread fastening glue Shift mechanism 11-13 positioning plate assembly Right crankcase cover bolt 11-13 Five star plate bolt 11-13...
Page 18: Torque Value - Body Part
Torque value - body part Note: The following standard parts are for regular edition models only Specificati Installation area Torsion N.m Note Self-tapping nails for the connection of the front brake fluid ST4.8 pipe pressure plate and the front shock absorbing trim Self-tapping nails for connecting rear fender liner and rear ST4.8 fender rear section...
Page 19 Specifica Installation area Torsion N.m Note tion Hexagon socket flower-shaped pan head screws for connecting side bracket flameout switch to side bracket Hexagon socket head screws for connecting the left and right front fuel tanks to the tank mounting bracket Hexagon socket head screws in front of the left and right front fuel tanks connected to the frame Hexagon socket head bolts connecting ignition lock to upper...
Page 20 Installation area Specification Torsion N.m Note Inner six flower hexagonal flange face bolts for the Threading connection of the rear disc brake disc to the wheel drum glue Inner hexagonal flower pan head step bolts for the connection of the rear water skin to the rear fuel tank Hexagonal flange face bolts for rear ABS sensor bracket to rear caliper bracket connection Inner six flower hexagonal flange face bolts for the rear...
Page 21 Installation area Specification Torsion N.m Note Hexagonal flange face bolts of the engine upper suspension connected to the bracket Hexagonal flange face bolts connecting the front engine suspension to the engine Special bolts for side brackets connected to the frame Hexagonal flange face bolts for connecting the U-shaped rocker to the frame Flat head bolts for connecting triangle rocker to...
Page 22 Note: The following standard parts are for factory edition models only Installation area Specification Torsion N.m Note Front brake oil pipe pressure plate and ST4.8X12 3N·m front shock trim attachment screw Rear mudguard lower cover and tail ST4.8X15/16 2N·m trim attachment screw Front and rear oil cup filler cap 3N·m fastening screws...
Page 23 Installation area Specification Torsion N.m Note Air filter cotton and air filter M5X78 4N·m housing fastening bolts Throttle cable adjusting nut 5N·m Clutch handle adjusting nut 2N·m Starter relay nut and main line 5N·m connecting bolt Main wire tower wire and 10N·m engine connection bolt Chain retainer and flat fork...
Page 24 Torsion Installation area Specification Note Headlight mounting bracket and cowl bracket TC4 titanium M6X13 10N·m attachment bolt alloy Rear brake disc trim and flat fork attachment TC4 titanium M6X13 10N·m bolts alloy Rear brake caliper trim and rear caliper TC4 titanium M6X13，...
Page 25 Installation area Specification Torsion N.m Note Rear tank vent fitting screws Screw thread with M6 4N·m Headlamp bracket and head cover Rubber bolt M6X12 nut 8N·m bracket connection bolt (rubber) M6X10 Frame and air filter housing connection Rubber bolt M6X12 nut 8N·m bolt M6X10...
Page 26 Installation area Specification Torsion N.m Note Front tank side mounting point TC4 titanium M8X30 22N·m with frame connection bolt alloy Upper connecting plate and TC4 titanium M8x35 22N·m damping fastening bolt alloy (Threading Front brake caliper with bottom M8x35 32N·m glue)TC4 barrel bracket connection bolt titanium alloy...
Page 27 Installation area Specification Torsion N.m Note Brake tubing and rear brake TC4 titanium M10X1.25x22 22N·m upper pump connection bolt alloy Engine sprocket fastening nut M10X22 45N·m Engine suspension with engine TC4 titanium M10x30x1.25 54N·m connection bolt alloy Direction handle lower holder TC4 titanium M10x35 34N·m...
Page 28 Installation area Specification Torsion N.m Note Headlamp bracket press plate M5X12 4N·m titanium mounting bolt alloy Headlight and headlight bracket M5X12 5N·m titanium mounting bolts alloy ECU to rear tank connection M5X12 4N·m titanium bolt alloy Radiator grille with radiator M5X12 5N·m titanium...
Page 29: Lubrication And Sealing Point - Engine Part
Lubrication and sealing point - Engine part Materials Location Note 1596 Crankcase coupling surface seal gum 1590 Magneto outlet The whole surface of the inner and outer rotors of the oil pump Valve rod sliding face and rod end Timing chain the entire surface Camshaft rolling surface Inner surface of cylinder bore Piston outer surface, piston pin hole...
Page 30: Lubrication And Sealing Point - Body Part
Front damping oil seal lip Special damping fluid Front damping and dust proof seal lip KHL 5 W Front shock absorbing end cover O ring KOVE special chain lube Whole surface of chain English or equivalent version Driving tooth fastening nut...
Page 31 Regular maintenance and adjustment 1 Overview ..........................30 2 Maintenance interval schedule (factory edition) ..........31 3 Maintenance interval schedule (regular edition) ..........32 4 Fuel Line Inspection ....................33 5 Spark plug inspection ....................33 6 Inspection and adjustment of valve clearance............. 35 7 Engine oil change......................
Page 32 32 Steering damper inspection and adjustment ........... 55 33 Steering Head Inspection and Adjustment ............56 34 Inspection and lubrication of front and rear wheel seals ......56 35 Lubrication of steering head bearings ............. 57 36 Inspection and lubrication of the triangular rocker ........57 37 Inspection and lubrication of the flat fork shaft ...........
Page 33: Overview
Maintenance information Overview： This chapter contains all relevant information for the recommended inspections and adjustments. If these maintenance procedures are carried out regularly, they will result in smoother running, longer life and lower maintenance costs. The information in this chapter applies to motorcycles already in use and not yet for sale.
Page 34: Maintenance Interval Schedule (Factory Edition)
I，* Wheel/tire Steering head bearing I，* We recommend referring to the official KOVE maintenance manual to repair these items. This maintenance schedule is based on average riding conditions. Frequent use of the vehicle requires more frequent maintenance. English Note: 1. Clean the motorcycle promptly after each ride.
Page 35: Maintenance Interval Schedule (Regular Edition)
Shock absorber oil R 5000km/100H *: This item is repaired by the personnel of KOVE locomotive special repair store. If the user has special tools, repair parts and repair ability, he can also repair by himself, and the repair knowledge can refer to this instruction manual.
Page 36: Fuel Line Inspection
※Fuel line inspection Before and after the tank inspection before remove the following content: - fuel tank vent; - seat cushion assembly; - before tank decoration or so; - remove the engine protection plate assembly; - disconnect the fuel pump power supply 2 p (black) joint.
Page 37: Spark Plug Inspection
※Spark plug inspection The following procedure applies to all spark plugs. Remove the following components. - Removal of the seat cushion assembly. - The front trim assembly. - The front fuel tank vent pipe. - Front left and right side fuel tanks. - Air filter assembly.
Page 38 ※Check of valve clearance Note: in cooler conditions, please check and adjust the valve clearance. Remove the following parts: - cylinder cover; - inspects a hole cover and o-rings [1]; - depending on the hole cover and o -rings [2]; 1.
Page 39: Inspection And Adjustment Of Valve Clearance
※ Inspection and adjustment of valve clearance Disassemble the following components. - Tensioner. - Camshaft bracket. - Chain press. 1. Turn the timing driven sprocket to the engine timing position: the positive time line mark of the timing driven sprocket is flush with the cylinder head end face [1],[2];...
Page 40 The thickness of the gasket [1] was measured and recorded. Note: gaskets to choose from, there are 69 different thickness is 0.025 mm from adjacent thickness (1.200 2.900 mm) with the following equation calculating the new gasket thickness: A = B (C) + D A: B: new gasket thickness record of valve clearance value C: regulation valve clearance value of...
Page 41 4. Installation of cylinder head cover Assemble the cylinder head cover sealing ring [1], spark plug hole sealant pad [2], head cover bolt buffer washer [4] in the designated position of the cylinder head cover. Will three cylinder epicranium fixed bolt M6 x 22.8 [5] and 3 cylinder epicranium fixed bolt M6 x 50.7 [6], in the cylinder head assembly, fastening, in turn, according to the...
Page 42: Engine Oil Change
※Engine oil change After starting the engine for a few minutes, turn off the engine and place a container under the oil drain bolt. Remove the following parts: - engine oil fuel cap [1]; - the oil discharge bolt and aluminum spacer; - the oil filter cover [2] and mesh, the right combination mesh bolts [3];...
Page 43: Throttle Valve Body Intake Pipe Inspection
※Throttle valve body intake pipe inspection 1. Remove the following components. - Seat cushions. - Front trim parts. - Fuel tank vent pipe. - Lower engine guards. - Front left and right side fuel tanks. - Air filter assembly. - Throttle valve body. 2.
Page 44: Inspection Of Evaporative Emission Activated Carbon Canister And Dump Valve
※Inspection of evaporative emission activated carbon canister and dump valve Disassemble the following components. - Removal of the seat cushion assembly. - Removal of the front trim assembly. - Removal of the front left and right fuel tank-vent pipes. - Removing the lower shield assembly. - Disconnecting the front left and right fuel tank connection fuel lines.
Page 45: Air Filter Sponge Element Replacement / Check Hose Cleaning
※Air filter sponge element Figure1 replacement / check hose cleaning Remove the following components. - Removal of the seat cushion assembly. - Removal of 2 profile bolts [1]. - Remove the air filter sponge [2]. Install in the reverse order of disassembly. 1.
Page 46: Exhaust System Inspection
※Exhaust system inspection 1. Remove the following components. - Seat cushion assembly. - Front trim parts assembly. - Lower engine guard assembly. Install in the reverse order of disassembly. Caution. -Wait for the muffler to cool down before checking to avoid hand burns. Figure 1,2 shows the regular edition model.
Page 47: Adjustment Of Clutch Free Travel
Exhaust mounting bolt torque： 1. Exhaust front section to engine connection nut: 22 N.m (2.2 kgf.m, 16 lbf.ft) 2. Exhaust middle section to frame attachment bolt: 22 N.m (2.2 kgf.m, 16 lbf.ft) 3. Exhaust rear section and bracket attachment bolts: 22 N.m (2.2 kgf.m, 16 lbf.ft) 4.
Page 48: Inspection Of Brake Operation
※Inspection of brake operation FRONT： 1. Check: • brake brake operation is not normal to check the brake system. Note: in dry road driving, and brake, before and after operation respectively to check the brake is working correctly. ※Inspection of front and rear brake pads Check the liner.
Page 49: 16Inspection Of Front And Rear Brake Fluid Lines
※Inspection of front brake fluid lines 1. Check: • brake tubing [1]; Crack/damage to replace. 2. Review: • brake pipe fixed [2]; Loose - > lock tighten bolts reservation. • brake tubing (bolt) [3]; Loose - > lock bolt. 3. Keep upright, vehicle braking action several times.
Page 50: Emission Of Air From Hydraulic Brake System
※Emission of air from hydraulic brake system （ABS） The following process applies only to factory edition vehicles • After removing brake related parts, be sure to exhaust the brake system air. Note: in the following order, discharge the air brake system. Step [1] [2] 1: before the brake calipers.
Page 51: Abs Gear Ring Clearance Inspection
The following are regular edition models: Air Emissions Operation Procedures (ABS) After the repairer has finished installing the ABS, there must be no gas in the line to ensure the ABS works properly. In this case, you need to use the diagnostic instrument to perform manual exhaust operation on the ABS.
Page 52: Inspection Of Brake Fluid Level
※Inspection of brake fluid level Note: do not use different types of brake fluid mixing are incompatible with each front： rear： other. Filling liquid storage tank, don't let the foreign matter to enter. Liquid level check:： Check the liquid level of the storage tank of the front and rear brake master pump.
Page 53: Adjustment Of Headlight Beam
※Adjustment of headlight beam Caution. -Adjust the headlight to the light according to the local laws and regulations. Support the motorcycle vertically on the horizontal plane. By turning the adjustment screw [1]. Turn clockwise to move the beam downwards. Turn counterclockwise to move the beam upward.
Page 54: Check Of Cooling Fluid Quantity
※Check of cooling fluid quantity 1. Stand up the vehicle on a flat surface. Caution. -Place the motorcycle on a suitable stand. -Make sure the motorcycle remains upright. 2. Check. - Coolant level The coolant level should be between the lowest level mark "a"...
Page 55: Inspection Of Cooling System
※Inspection of cooling system 1. Check: radiator [1]; About the radiator, connecting hoses [2]; The radiator water hose [3]; • radiator inlet hose [3]; Crack/damage to replace. 2. Review: oil cooled radiator [1]; Gives oil, oil cooled radiator hose [2]; •...
Page 56: Coolant Change
※Coolant change When adding coolant to the tank radiator or sub-tank or checking the coolant dosage, the motorcycle should be placed on level level and in an upright position. Remove/install remove the following parts: - remove the front guard board under the right side of the tank and assembly;...
Page 57: Lubrication Of Front Brake Handle
Lubrication of front brake handle Lubricate the pivot point of the handle and the contact part of the metal [1]. Recommended Lubricants Use of silicone grease Recommended Lubricants Lithium-based multi-purpose grease ※Lubrication of the rear brake arm The pivot point of the lubricating foot and the contact part of the metal [1].
Page 58: Steering Damper Inspection And Adjustment
※Steering damper inspection and adjustment 1. Stand up the vehicle on a flat surface. Caution. -Make sure the motorcycle remains upright. 2. Check that. - whether the front end dampers are working properly by holding the handlebars and turning them left and right [1]. Improper damping/stalling →...
Page 59: Steering Head Inspection And Adjustment
※Steering Head Inspection and Adjustment 1. Set up the bike on a flat surface. •The bike must be firmly supported and there is no danger of tipping over Notes. Place the motorcycle on a suitable stand so that the front wheel is elevated. 1.
Page 60: Lubrication Of Steering Head Bearings
※Lubrication of steering head bearings Regularly clean, inspect and lubricate steering head bearings especially on wet, muddy or dusty surfaces. Using high temperature extreme pressure lithium complex base grease (optimal sheng SU - T330G grease or similar grease) lubrication. Recommended Lubricants Lithium-based multi-purpose grease ※Inspection and lubrication of the...
Page 61: Inspection Of Wheel Tires
※Inspection of wheel tires Check the tires for cuts, embedded nails or other damage. Check that the front and rear wheels are properly mounted and check the tire pressure with a tire pressure gauge when the tires are cold. Regular edition tire pressure (vacuum tires). Front side: 200kPa (2.0kgf/cm³, 29 psi) Rear side: 200kPa(2.0kgf/cm³, 29 psi) Regular edition tire pressure (inner tube)
Page 62: Replacement Of Tires
※Replacement of tires 450rally factory edition tire： 90/90-21M/C 54R KOVE tires provide excellent front handling, braking, durability and tire Zhengxin/CST EX02F comfort in all riding conditions. 140/80-18M/C 70R rear tire Zhengxin/CST EX02R • Installing the wrong tires on a motorcycle can affect handling and stability.
Page 63: Inspection Of Chain Guide Box
※Inspection of chain guide box Check the chain guide box [1] for deformation and damage. Damage/deformation and replacement. Note: if the chain guide box of metal framework, impact transmission chain, fall off, lead to transmission chain worn or noise. Check the transmission chain guide rail sliding block [2] for wear.
Page 64: Inspection And Adjustment Of Transmission Chain Tightness
※Inspection and adjustment of transmission chain tightness •Do not check or adjust the engine while it is running Inspection. Lift the drive chain at the position shown and measure the distance from the upper surface of the rear flat fork. Tightness Standard: 35-55mm diagram...
Page 65: Inspection Cleaning And Lubrication Of The Drive Chain
※Inspection cleaning and lubrication of the drive chain Note: • to ensure the service life of the chain and the intensity of single truncation chain is prohibited. For maximum service life, after each driving should be clean and smooth transmission chain. Service 1: measuring the height of the limit...
Page 66: Transmission Chain Replacement
※Transmission chain replacement Disassembly/Installation Remove the following parts. - Remove the chain guide box [1]; - Remove the small sprocket trim cover [2]; - Remove the triangle rocker and flat fork attachment bolts [3]; - Remove the lock nut of the flat fork shaft and take out the flat fork shaft [4];...
Page 67: Inspection Of Front Shock Absorber And Rear Shock Absorber
※Inspection of Front Shock Absorber Front Shock Absorber 1. Stand up the vehicle on a flat surface. •The bike must be firmly supported without the risk of tipping over. 2. Review: • tube damage/scratch and replacement. , between the bottom of the shock absorber tube tube and appearance before the spill to replace oil seal.
Page 68: Front Shock Absorber Air Pressure, Compression And Rebound Damping Adjustment
※Front shock absorber air pressure adjustment The pressure inside the shock acts as a progressive spring, affecting the front reduction throughout its travel. Air is an unstable gas and his pressure increases when he does his work (inside the shock cavity), so the front shock on this motorcycle will become stiff as the race progresses.
Page 69: Rear Shock Absorber Spring Preload Adjustment
※Front reducer rebound damping adjustment The rebound damping adjustment affects the speed of the front shock rebound. The front shock rebound damping has 22 segments. Each segment is 1/4 turn. By turning the rebound damping adjustment bolt one full turn, the adjuster will turn 4 segments. Turn the adjusting bolt clockwise to increase the rebound damping (hard) and counterclockwise to decrease the rebound damping (soft).
Page 70: Rear Shock Absorber High Speed, High And Low Speed Compression Damping Adjustment
High seat version. Increase spring preload. Loosen the shock spring lock nut with an active wrench, turn the adjusting nut and shorten the spring length, the shortest should not be less than: 215mm. Decrease the spring preload. Loosen the locking nut of the damper spring with an adjustable wrench, turn the adjusting nut and increase the spring length up to a maximum of: 230 mm.
Page 71: Rear Shock Absorber Rebound Damping Adjustment
2. Low-speed compression damping adjustment High speed compression When damping adjustment is required at damping adjustment bolt relatively low speeds, the low-speed compression damping adjustment bolt should be used. The low-speed compression damping adjustment bolt has 16 segments, each segment is 1/4 turn. The dampers become stiffer after turning clockwise (H) and softer after turning Low speed compression...
Page 72: Vehicle Locking Torque Inspection
※Motorcycle locking torque inspection Check that all nuts, bolts and screws are properly locked (every 3 months or 1000km). Torque values - 1-13 pages of "moment of torque value - the engine, car body parts". ※ Inspection of brake light switch Brake light switch inspection 1.
Page 73: Adjustment Of Throttle Free Travel
※Adjustment of throttle free travel 2-6 mm (0.08-0.24 in) Check that the throttle cable is not aged, damaged or kinked. Turn the throttle handle and check that the throttle opens smoothly and closes automatically in any steering position. If the throttle handle does not turn smoothly and smoothly, check that the cable is properly routed, that the throttle lever is clean and lubricated with the recommended lubricant (engine oil or appropriate cable...
Page 74: English 60 Inspection And Damage Lubrication Of Steel Cable
※Inspection and damage lubrication of steel cable The following procedures apply to all steel cables. 1. Inspection. - Outer steel cable Damage → Replace. 2. Check. - Cable operation Uneven movement → Lubrication. Recommended lubricants Engine oil or suitable steel cable lubricant Note: the end of a rope self-reliance, the number will be lubricant drops into the wire, or using the...
Page 75 Frame, body trim, exhaust system 1 Maintenance information ..................73 2 Body trim location/removal diagram ..............74 3 Seat cushion assembly .................... 75 4 Front trim assembly (left and right), front windshield ......... 76 5 Front headlight housing, front fender .............. 77 6 Front shock absorber trim parts (left and right), front brake fuel line pressure plate ........................
Page 76 Maintenance information Overview. -This section describes the removal and installation of body trim and exhaust systems. -When removing, mark and store the installation fasteners to ensure that they are reinstalled in their original locations. -When installing the valve cover, ensure that the mating areas are properly aligned before tightening the fasteners.
Page 77 Body trim location/removal diagram [17] [18] [19] [21] [20] [16] [15] [6] [7] [8] [9] [10] [11] [12] [13] [14] （15）muffler rear （1） Front decoration assembly (8)engine lower guard plate section （16）Rear position （2）Headlight (9) Shift arm light （17）Road book （3）Front fender (10)Footrest （4）front shock absorber...
Page 78 ※Cushion assembly Disassembly/Installation Remove the following components. Pull down on the seat pull cable while pulling the rear end of the seat up and out of the lock, then remove Seat lock the seat diagonally upward to the rear. latch Install the seat cushion：...
Page 79 ※Front trim assembly Disassembly/Installation Remove the following parts. - Remove Fig. 1, Fig. 2 - 3 left and right 1/4-turn quick-lock bolts at position [1]. - Removal of the front trim of the fuel tank. Install in the reverse order of disassembly.
Page 80 ※Headlamp cover Disassembly/Installation Remove the following components. - Remove the 4 hexagon socket step pan head step screws [1]; Install in the reverse order of disassembly. ※Front fender Disassembly/Installation Disassemble the following parts. - Remove 4 inner hexagonal flange bolts [1] and 4 flat washers 4 flanged bushings;...
Page 81 ※Front shock absorbing trim parts (left and right) Disassembly/Installation Disassemble the following components. - Removal of 3 hexagonal flower head step bolts [1]. - Removal of the front shock absorber trim right. - Removal and installation of the left shock absorber trim member as above.
Page 82 ※Rear tank protective cover Disassembly/Installation Remove the following components. - Remove the 5 hexagonal countersunk head screws [1]. - Removal of the rear fuel tank protective cover [2]. Install in the reverse order of disassembly. ※Rear wheel water barrier leather Disassembly/Installation Disassemble the following parts.
Page 83 ※Rear tail cover (factory edition) Figure1 Disassembly/Installation Remove the following components. - Removal of 2 hexagonal pan head bolts [1] in the position of Fig. 1. - Removal of 2 tailpack mounting step bolts [2] in the position of figure - Removal of 3 cross slotted large pan head self-tapping bolts [3] in position Figure 2.
Page 84 ※Rear tail cover（regular edition） Disassembly/Installation Disassemble the following parts. - Remove 2 hexagonal pan head bolts [1]; - Remove 2 tail pack mounting step bolts [2]; - Remove 3 self-tapping nails [3]; - Remove the rear tailcap [4]; The installation order is the reverse of the disassembly order.
Page 85 ※Engine sprocket cover Disassembly/Installation Remove the following parts. - Remove the 2 small sprocket cover bolts [1]; - Remove the small sprocket cover [2]; The installation order is the reverse of the disassembly order. ※Chain guide box Disassembly/Installation Disassemble the following parts. - Remove 2 x M6x55 hexagonal socket head cap screws [1];...
Page 86 ※Chain Guard upper lower Disassembly/Installation Disassemble the following parts. - Remove 2 Phillips half-round head screws [1], [2] from the upper part of the flat fork; - Remove 1 Phillips half-round head screw from the lower part of the flat fork [3]; - Remove the chain guard [4];...
Page 87 ※Hand windshield-(left and right) （factory edition） Disassembly/Installation Remove the following components. - Removal of 3 hexagon socket step screws [1]. - Removal of hexagon socket countersunk head screws [2]. - Removal of 2 inner hexagonal socket head flange bolts [3]. - Remove the hand windshield bracket [4].
Page 88 ※Engine lower guard assembly Disassembly/Installation Disassemble the following parts. - Removal of 5 inner hexagonal flange bolts [1]. - Remove the lower shield assembly [2]. Install in the reverse order of disassembly. ※Oil cooling grille Disassembly/Installation Remove the following components. - Removal of 2 hexagonal screws [1].
Page 89 ※Rearview mirror assy (regular edition) Disassembly/Installation Disassemble the following parts. - Loosen the nuts [1]. - Rotate the rearview mirror until the mirror [2] is removed. - Removal and installation of the right side mirror as for the left. The installation order is the reverse of the removal order.
Page 90 ※Left and right side of foot pedal assembly Disassembly/Installation Disassemble the following parts. - Removing the cotter pin and flat pad [1]. - Removal of the main foot pin [2]. - Removing the foot pedal [3] and torsion spring [4]. - Installing and disassembling the same left and right.
Page 91 ※exhaust assembly（regular edition） 1. Exhaust mid-section, tail section Removal/Installation Remove the following components. - Removal of the hoop locking bolt [1]. - Remove the exhaust tail section locking bolt [2]. - Removing the exhaust tail section [3]. - Remove the exhaust mid-section bolt [4]. - Loosen the hoop locking bolt [5].
Page 92 1. Overview ...................... 90 2 System Location ..................91 3 EFI System Related Components ............92 4 Introduction to System Troubleshooting Functions ....105 5 Inspection and Diagnosis Process ............. 109 6 Troubleshooting based on fault codes .......... 109 7 Troubleshooting based on fault phenomena ......118 8 Fault Code List..................
Page 93: Overview
1. Overview: -This section introduces the EFI system service of MSE8.0, which is equipped with self-diagnostic function, when troubleshooting, please check and troubleshoot according to the fault diagnosis code and fault phenomenon. -EFI system failure is usually related to poor connector connection or connector corrosion, please check the connector before troubleshooting.
Page 94: System Location
2. System location Racing version Ignition coil spark plug Throttle Oxygen Assembly Sensor Civilian version Ignition coil spark plug ECU Control Unit Oxygen Throttle Sensor Assembly English version...
Page 95: Efi System Related Components
3. EFI system-related components 3.1 ECU electronic control unit The electronic control unit is the brain of the entire EFI system and electrical appliances. It analyzes and processes the various information provided by the sensors and sends the resulting conclusions in the form of commands to the actuators so that the engine runs in ECU Form Factor an optimal state.
Page 96 3.2 Ignition Coil Ignition coil shape drawing The ignition coil converts the low voltage electricity from the primary winding to the high voltage electricity from the secondary winding, which is discharged through the spark plug to produce Fig. 1 a spark that ignites the fuel mixture in the cylinder.
Page 97 3.3 Spark plug Caution. -Before removing the spark plug use an air gun to blow and clean the spark around the plug base and also make sure that no dust has fallen into the cylinder. 1. Check. ● Spark plug type Incorrect →...
Page 98 Injector profile drawing 3.4 Injector One end of the injector is mounted on the injector holder, and the other end is connected to the fuel pipe through the injector cap. It injects fuel within the specified time according to the instruction of ECU, by which fuel is supplied to the engine and atomized.
Page 99 3.5 Fuel Pump Fuel pump outline drawing The fuel pump assembly and the wiring diagram of the connection with the fuel pump relay ECU. This fuel pump assembly integrates a fuel pump, a plastic holder coarse and fine filter and a regulator, which works to pump fuel from the fuel tank to the engine at a certain oil pressure and flow rate.
Page 100 3.6 Throttle Body Assembly Fig1 Connects the air filter and engine, controls the opening and closing angle of the throttle plate by the throttle cable, and sends the turning angle signal to the ECU by the throttle position sensor. As shown in figure 1 on the right sensor locations.
Page 101 3.7 Three-in-one sensor Intake air temperature The intake air temperature sensing element is a negative temperature coefficient (NTC) resistor, the resistance of which varies with the intake air temperature. This sensor delivers a voltage to the ECU controller that indicates the change in intake air temperature.
Page 102 3.8 Idle stepper motor Control the flow of bypass airflow, stepper motor by the ECU according to the engine load, through the engine sensor to control the stepper motor in different operating conditions, the injection volume is also different, so the stepper motor is needed to make up the air intake, so it should be connected according to the specified connection, otherwise it...
Page 103 3.9 Oxygen sensor This sensor is used in the feedback system of the electronically controlled fuel injection device to achieve closed-loop control and improve the accuracy of the ECU's control of the air-fuel ratio, which is installed on the front section of the exhaust pipe to determine the oxygen content in the Oxygen Sensor Outline Drawing exhaust gas to determine whether the...
Page 104 3.10 Engine water temperature sensor This sensor is two sets of negative temperature coefficient (NTF) thermistor, its resistance value decreases with the increase of coolant temperature, but not a linear relationship. One group is provided to the ECU to monitor the thermal status of the engine, and A group is provided to the ECU for the water temperature signal.
Page 105 3.11 Sway sensor The role of this sensor for the side tilt protection, that is, when the car side tilt angle exceeds the allowable angle (65 ° ± 10 °), OUT pin signal to the ECU, the ECU control engine off, so as to achieve the protection of the driver and the vehicle.
Page 106 3.12 Side bracket switch Check Disconnect the side stand switch 3P (white) connector [1]. Check the switch side connector terminal. The vehicle can be started normally when the side stand is lowered, and automatically turns off after shifting. When the side stand is retracted, the vehicle can be started and Fig1 driven normally in gear.
Page 107 3.13 Trigger Provide the engine speed signal to the ECU, and the ECU determines the ignition angle, injection phase, etc. based on this signal. Trigger profile drawing Fig1 Fig 1: The wiring diagram of the trigger and ECU Measure the resistance value of the trigger.
Page 108: Introduction To System Troubleshooting Functions
4. System fault diagnosis function introduction On-board diagnostic system (OBD system) is a diagnostic system integrated in the engine control system that can monitor the status of components affecting exhaust emissions and the main functions of the engine. It has the function of identifying and storing EFI faults. When repairing a vehicle with OBD system, the repairer can quickly and accurately locate the malfunctioning parts through the diagnostic instrument, which greatly improves the efficiency and quality of repair.
Page 109 4.3 OBD Interface Introduction Pin 4, 7 and 16 on the OBD diagnostic connector are used for EMS with engine management system. Pin 4 of the standard diagnostic connector is connected to the negative terminal of the battery; pin 7 is connected to pin E3 of the ECU, which is the "K"...
Page 110 4.4 Maintenance tools Tool. EFI system diagnostic instrument Function. Read/clear EFI system fault codes and observe data flow. Tool: EFI system adapter Function. Check the electrical signal of each pin of the electronic control unit, check the wiring condition, etc. Tool: Ignition Timing Light Function.
Page 111 Tool: Vacuum table Function. To check the pressure in the intake manifold. Tool: Cylinder pressure gauge Function. Check the cylinder pressure of each cylinder. Tool: Fuel pressure gauge Function. To check the pressure of the fuel system to determine the fuel system pump and fuel pressure regulator in the fuel system.
Page 112: Inspection And Diagnosis Process
5. Inspection and diagnosis process 5.1 How to use the diagnostic instrument 1. Connect the diagnostic instrument to the diagnostic interface. 2. Turn on the "ignition switch". 3. Read fault-related information (fault codes, freeze frames, etc.); check the repair manual to confirm the defective parts and types; develop a repair plan based on fault-related information.
Page 113 6.1error code: P0030 oxygen sensor heating control circuit open circuit or P0053 oxygen sensor heating unreasonable Repair Tip. Repair Tips. Check the following items The fault has been identified as possibly (1) Measure the resistance of the line having the following problems between the ECU connector pin and the (1) Open circuit between the circuit upstream oxygen sensor pin 2 and...
Page 114 6.7 Error code: P0106 Intake pressure sensor circuit signal untrustworthy Repair Tip. Repair Tip. Check the following items The fault has been identified as possibly 1) The presence of a serious air leak in the having the following problems 1) The intake pressure sampling value intake system.
Page 115 6.13 error code: P0118 Engine coolant temperature sensor circuit voltage is too high Repair Tip. Repair Tip. Check the following items The fault has been identified as possibly 1) Measure the voltage connected to the having the following problems ECU pin to see if it is normal. 1) Short circuit between the circuit connected to the ECU pin and other power circuits.
Page 116 6.19 error code: P0131 Oxygen sensor circuit voltage is too low Repair Tip. Repair Tip. The fault has been identified as possibly Check the following items having the following problems 1) Measure the resistance between the 1) The signal circuit connected to the ECU signal circuit connected to the ECU pin pin is shorted to ground.
Page 117 6.24 error code: P0261 One-cylinder injector control circuit short circuit to ground Repair Tip. Repair Tip. The fault has been identified as possibly Check the following items having the following problems 1) Measure the resistance of the circuit 1) Each drive circuit circuit connected to connected to the ECU pin to ground.
Page 118 6.29 error code: P0459 carbon canister control valve control circuit voltage is too high Repair Tip. Repair Tip. The fault has been identified as possibly Check the following items having the following problems 1) Measure the voltage at the ECU pin to see 1) Short circuit between the circuit if it is normal.
Page 119 6.33 error code: P0650 MIL lamp driver stage circuit failure Repair Tip. Repair Tip. The fault has been identified as possibly Check the following items having the following problems 1) Measure the resistance or voltage of 1) open circuit/short circuit to the MIL lamp driver circuit connected to ground/short circuit to power supply in the ECU.
Page 120 6.38 Error code: P2177 Non-idling mixture is too lean Repair Tip. Repair Tip. The fault has been identified as possibly Check the following items having the following problems 1) Whether the fuel pressure regulating 1) Low oil supply pressure. valve (3.5 bar) is normal. 2) Insufficient oil supply.
Page 121: Troubleshooting Based On Fault Phenomena
7. Troubleshooting according to the fault phenomenon This section introduces the meaning of the current fault phenomenon, the corresponding diagnosis strategy and possible causes of the fault, as well as the treatment strategy of the fault, which can be referred to during the vehicle maintenance.
Page 122 7.3 Difficult to start when cold and hot. General fault parts: 1, fuel containing water; 2, fuel pump; 3, engine temperature sensor; 4, injectors; 5, ignition coil; 6, throttle body and idle bypass airway; 7, engine mechanical parts. General diagnostic process. Procedure Testing results Following Steps...
Page 123 7.4 Start normally, but idle speed is unstable at any time. General fault parts: 1, fuel containing water; 2, injector; 3, spark plug; 4, throttle body and idle bypass airway; 5, air intake; 6, idle speed regulator; 7, ignition timing; 8, spark plug; 9, engine mechanical parts.
Page 124 7.5 The speed does not go up or stalls when accelerating. General fault parts: 1, fuel containing water; 2, intake pressure sensor and throttle position sensor; 3, spark plug; 4, throttle body and idle bypass airway; 5, intake airway; 6, idle speed regulator;...
Page 125 7.6 Slow response during acceleration. General fault parts: 1, fuel containing water; 2, intake pressure sensor and throttle position sensor; 3, spark plug; 4, throttle body and idle bypass airway; 5, air intake; 6, idle speed regulator; 7, fuel injector; 8. Ignition timing;...
Page 126: Fault Code List
8. Annexes: •-List of error codes (PCODE) Error Instructions（ UAES） Code P0030 Oxygen sensor heating control circuit open circuit P0031 Oxygen sensor heating control circuit shorted to ground P0032 Oxygen sensor heating control circuit shorted to power supply P0053 Oxygen sensor heating unreasonable P0107 Intake pressure sensor shorted to ground P0108...
Page 127 Fuel System 1 Maintenance information ..................125 2 Parts Location ......................126 3 Fuel Line Inspection ....................127 4 Fuel Pressure Relief ....................127 5 Quick Connect Removal ..................128 6 Quick Connect Head Installation ..............129 7 Increasing Fuel Pressure ..................130 8 Fuel pump unit .......................
Page 128: Maintenance Information
Maintenance information Overview -Bending or twisting control cables can interfere with smooth operation and can cause cables to stick or become tangled, which can cause loss of vehicle control. -Work in a well-ventilated area. Smoking or allowing flames or sparks in the work area or where gasoline is stored can cause a fire or explosion.
Page 129: Parts Location
Parts Location Dumping valve Throttle Valve fuel pump carbon tank English version...
Page 130: Fuel Line Inspection
※Fuel Line Inspection Before and after the tank inspection before remove the following content: - fuel tank vent; - seat cushion assembly; - before tank decoration or so; - remove the engine protection plate assembly. Inspection. Hang the front left fuel tank on the left side of the frame 1.
Page 131: Quick Connect Removal
※ Quick Connect Removal Disassembly Caution. -Before disconnecting the fuel supply hose, clean around the quick disconnect and make sure no dirt enters the fuel system. Do not bend or twist the fuel supply hose. This may cause a fuel leak. [1] [2] 1.
Page 132: Quick Connect Head Installation
※ Quick Connect Head Installation Caution. -Do not bend or twist the fuel supply hose, this may cause fuel leaks. -Do not reuse kinked or damaged fuel supply hoses. -Do not use gloves or rags when installing quick-connect couplings. 1. Connect quick-connect fittings [1], [2] to the fuel pump unit connector and injector connector, respectively, while holding the quick-connect...
Page 133: Increasing Fuel Pressure
※Increasing Fuel Pressure 1. Connect the fuel pump power supply wire quick plug connector (black) 2p[1]; 2. Temporarily left before the fuel tank is installed on the frame; 3. In the case of throttle fully closed, pull the clutch handle to the bottom, and press the starter switch;...
Page 134: Fuel Pump Filter
※Fuel pump filter Remove/check/installation dismantling the pump unit disconnect pump motor wiring harness connector [7], [8]. As shown, open fuel pump bracket left and right sides of the card buckle [1], [2], remove the fuel pump bracket. Note: • don't use tools in order to avoid damage to the pump unit.
Page 135: Front Side Fuel Tank And Rear Fuel Tank Mounting Fuel Line Connection Check
※Front side fuel tank and rear fuel tank mounting fuel line connection check Disassembly/Installation Remove the following. Before installing the fuel tank, disconnect the fuel pump supply line speed connector fuel line quick release connector. -Check the P1 rubber screw bolt [1] for looseness, breakage, and deterioration.
Page 136: Efi (Evaporative Fuel Emission) Carbon Canister/Dump Valve
※EFI (evaporative fuel emission) carbon canister/dump valve （regular edition only） Disassembly/Installation Disassembly of the following. - Disassembly of the dump valve and carbon tube. - Removal of the lower engine guard assembly. - Removal of the left front fuel tank. - Disconnecting the fuel tank connecting dump valve hose [1], connecting dump valve carbon tube...
Page 137: Air Filter Assembly
※Air filter assembly Remove the air filter housing assembly from the frame by loosening the air intake hose [1] toward the rear and from the throttle side. Install in the reverse order of removal. Caution. - When placing the assembly into the frame, carefully install the crankcase breather hose [2], making sure it is not kinked or deformed.
Page 138: Throttle Free Travel
※Throttle Free Travel 2-6 mm (0.08-0.24 in) Check that the throttle cable is not aged, damaged or kinked. Turn the throttle handle and check that the throttle opens smoothly and closes automatically in any steering position. If the throttle handle does not turn smoothly and smoothly, check that the cable is properly routed, that the throttle lever is clean and lubricated with the recommended lubricant...
Page 139: Throttle Assembly And Air Intake Hose
※Throttle assembly and air intake hose ①. Throttle Removal/Installation Remove the following parts. - Remove the fuel line quick coupling [1]; - Remove the fuel rail cap mounting screw [2] and the fuel rail mount injector; - Disconnect the triple sensor plug 5p [3];...
Page 140: Throttle Valve Body
Throttle Valve Body Removal/installation note: • throttle body, is the factory assembly good way to remove the outside not shown in this manual. , throttle pull don't will throttle after removed from open to close, which may lead to damage of throttle. Don't damage the throttle body;...
Page 141: Oil Rail Assembly
※Oil rail assembly Removal/Installation Remove the oil rail assembly from the throttle assembly. Remove the following parts. - 1 bolt [1]; - 1 wire harness connector [2] ; - Remove the oil rail [3]; - Remove the injector clips [4]; - Remove the injector [5];...
Page 142 Cooling System 1 Maintenance information ................140 2 Cooling System Flow Chart ................141 3 Cooling System Test ..................142 4 Coolant change....................143 5 Thermostat ......................145 6 Water reservoir, radiator grille ..............146 7 Fans, water pipes, radiators ................147 8 Water pump ......................
Page 143: Maintenance Information
Maintenance information Overview Do not remove the radiator cap before the engine and radiator cool down to prevent the coolant from splashing out and scalding people NOTE The use of coolant with silicate inhibitors can lead to premature wear of water pump seals or blockage of radiator passages.
Page 144: Cooling System Flow Chart
Cooling System Flow Chart Oil Cooled Radiator fan left Siphon Tube Thermostat Radiators Engine Intake Water reservoir Radiator cap 17 Radiator grille Hose Engine outlet English Radiator left Water pump pipe version Radiator left and right Radiator fan Oil-cooled radiator connecting pipes right inlet pipe...
Page 145: Cooling System Test
※Cooling System Test Radiator system pressure check. Disassembly/Installation Removal of the following components. - Removal of the front trim assembly. - Remove the radiator cap [1]. Lubricate the sealing surface of the cap [1]; then install the cap on the tester [2].
Page 146: Coolant Change
※Coolant change When adding coolant to the tank radiator or sub-tank or checking the coolant dose, the motorcycle should be placed on a level flat surface and in an upright position. Disassembly/Installation Remove the following components. - Removal of the front right side fuel tank and lower guard assembly.
Page 147 Disconnect the siphon hose from the radiator [1] and pull the siphon hose out of the hose clamp. Place the hose in a lower position outside the engine frame and drain the coolant from the storage tank. Drain the coolant, flush the inside of the storage tank with water, and install the hose into the hose clamp and over the radiator...
Page 148: Thermostat
※Thermostat Remove/install - emptying of coolant. - remove the bolts [1] and [2] thermostat cover. Remove the thermostat from the cylinder head [1]. Install in the reverse order of removal. Torque. Thermostat cover bolts. 12 N.m (1.2 kgf.m, 9.0 lbf.ft) Caution.
Page 149: Water Reservoir, Radiator Grille
※Water reservoir Disassembly/Installation Remove the following components. Drain the sub kettle coolant . - Remove the sub kettle mounting bolts [1]; - Remove the siphon hose clamps [2]. - Remove the sub kettle [3]. Install in reverse order of removal. Torque : Reservoir mounting bolts.
Page 150: Fans, Water Pipes, Radiators
※Fans Disassembly/Installation Disassemble the following components. - Drain radiator tank coolant; - Disconnect the radiator fan motor 2P (white) wire harness connector; - Remove the radiator fan left and right side mounting 6 bolts [1]; - Remove the radiator fans on the left and right sides.
Page 151: Water Pump
※Water pump End face seal inspection. Make sure there is no continuous coolant leakage when starting the engine. If necessary, replace the water pump as an assembly. Caution. Place a clean oil pan under the engine, coolant will flow when the water pump body is removed. After installation, add the specified coolant.
Page 152: Oil-Cooled Radiators
※ Oil-cooled radiator Make sure there is no continuous oil leakage when starting the engine. If necessary, replace the oil cooled radiator as an assembly. Caution. Place a clean oil pan under the engine where oil will escape when the oil cooled radiator is removed.
Page 153 Engine removal/installation 1 Maintenance information ..................151 2 Parts Location ......................152 3 Engine Removal ......................153 4 Engine Installation ....................157 English version...
Page 154: Maintenance Information
Maintenance information Overview Removing and installing, you need to use professional table or equivalent to support the motorcycle. You need to use a jack or other adjustable bracket to support and control the engine English version...
Page 155: Parts Location
Parts Location [1] [1] [12] [10] [11] Engine upper suspension and Engine and front suspension 36N.m [7] 54N.m frame attachment bolts x4 connecting bolts Self-locking nuts for engine Engine upper suspension and front suspension 54N.m bracket left and right connection Engine upper suspension and Engine front suspension 54N.m [9]...
Page 156: Engine Removal
※Engine Removal - Removing the seat cushion assembly. - Disconnecting the negative battery terminal. - Removing the front trim assembly. - Removing the lower engine guard assembly. - Removing the fuel tank vent pipe. - removing the front left and right side fuel tank and fuel pump connector fuel line quick release fittings.
Page 157 ④ Air filter assembly Installation / Disassembly Remove the following parts. - Remove the air filter assembly left and right 2 side bolts [1], [2]; - Remove the air filter assembly connecting the throttle intake pipe holding hoop [3]; - Remove the air filter assembly [4]. The installation order is the reverse of the disassembly order.
Page 158 ⑥ Oil-cooled radiator Keeps the motorcycle upright on level ground. Disassembly/Installation Remove the following parts. - Removal of the inlet and outlet oil pipe over oil bolts [1], [4]. - Remove the oil-cooled radiator mounting bolts [2]. - Remove the oil-cooled radiator [3]. The installation order is the reverse of the disassembly order.
Page 159 ⑦ ABS pump Disassembly/Installation Disassemble the following components. Drain the brake fluid from the front and rear brake hydraulic system. - Seat cushion assembly. - Air filter assembly. - ABS pump bracket. Disconnect the ABS pump 18P (black) connector Remove the brake hose brake light switch nut [1] and the upper and lower 2 sealing washers [2].
Page 160: Engine Installation
⑧ Engine Disassembly/Installation Remove the following parts. - Removal of bolts [1] engine outlet pipe hugger [2]. - Remove the rear flat fork shaft nut [3] to remove the rear flat fork shaft [6] and spacer. - Remove the engine upper suspension left and right attachment bolts [4] and [5].
Page 161 Cylinder head and valve 1 Maintenance information ................159 2 Troubleshooting .................... 160 3 Cylinder head assembly drawing .............. 161 4 Disassembly of cylinder head cover ............163 5 Disassembly of cylinder head ..............163 6 Disassembly of the cylinder head ............... 164 7 Inspection of valves and valve springs .............
Page 162: Maintenance Information
Maintenance information Overview -This chapter covers maintenance and inspection of cylinder heads, valves, camshafts, and tappets. -When repairing the cylinder head, camshaft and tensioner, judge whether the engine needs to be removed from the frame according to the model and shade; when repairing the cylinder head and valve, the engine must be removed from the frame.
Page 163: Troubleshooting
1.Troubleshooting Low air pressure in the cylinder. 1. valves. Incorrect adjustment of valve clearance. Poor valve sealing. incorrect air distribution timing. Broken valve springs. 2, cylinder head The spark plug is not tightly connected to the cylinder head. Damaged cylinder head gasket. Cracks or sand holes in the cylinder head.
Page 164: Cylinder Head Assembly Drawing
A. Cylinder head assembly drawing. (1) Small plate bolt M6×40_7 grade 24h. (2) Small plate bolt M6×35_7 grade 24h. (3) NC450S camshaft bracket. (4) NC450S chain pressure plate. (5)Small plate bolt M6×16_7 grade 24h. (6)NC250S camshaft stopper. (7)NC450S camshaft pressure reducing valve.
Page 165 (13) NC450S valve spring upper seat. (14)CB125 foot valve locking clip (improved type). (15)NC450S valve inner spring. (16)NC450S valve outer spring. (17)CG125D oil shield combination. (18)CG125D inner valve spring seat (lower). (19)NC450S outer valve spring seat (20)NC450S intake valve (rod diameter φ5.5) (21)NC450S exhaust valve (rod diameter φ5.5)
Page 166: Disassembly Of Cylinder Head Cover
Disassembly of cylinder head cover heteroshape 1、Remove the 3 NC450S cylinder heteroshape head cover fixing bolts (shaped M6×22.8) and 3 NC450S cylinder head cover fixing bolts (shaped M6×50.7). fixing bolts (shaped M6×22.8), 3 NC450S cylinder head cover fixing bolts (shaped M6×50.7). 2、Remove the head cover and the head cover gasket.
Page 167: Disassembly Of The Cylinder Head
Disassembly of cylinder head valve lifter 1, remove the four pieces of valve tappet, respectively, a good corresponding mark. 2. Remove the 2 NC450S thermostat cover fastening bolts M6×20 and remove the NC450S thermostat cover and the NC450S thermostat. thermostat cover 3、Use the valve remover to press thermostat down the valve spring and remove...
Page 168: Inspection Of Valve Tappet, Camshaft, Cylinder Head
Inspection of valve tappet Check the front and side of the tappet for abnormal wear. If the wear and tear is serious or the clearance is large after installation, a new tappet is required. Inspection of camshaft 1. Check whether the camshaft surface is worn and destroyed.
Page 169: Assembly Of Cylinder Head Components
Assembly of cylinder head components 1, the valve spring lower seat (3, 4), oil shield (5) installed on the valve guide. 2, the intake valve rod (1), exhaust valve rod (2) coated with a small amount of lubricant, installed into the valve guide, installed the valve outer spring (6), valve inner spring (7), valve lock clip (8) and valve spring upper seat (9).
Page 170: Installation Of Cylinder Head
Assembly of cylinder head components Cylinder stud AB(M10×152) 1、Remove the camshaft bracket that has been flat washer adjusted for the valve clearance cylinder head, and then remove the intake and exhaust camshaft parts. 2、Remove the old cylinder head gasket, install the new cylinder head gasket, and then install the cylindrical pin (∅6×12).
Page 171: Installation Of Cylinder Head Cover
6、After adjusting the timing position, assemble the large viewport cover and small viewport cover to the left front cover. 7. Then install the removed camshaft bracket, spark plug seal and chain pressure plate onto the cylinder head, and tighten 8 bolts of the cylinder head bracket, tightening bolts in the order of 1→2→3→4→5→6→7→8.
Page 172 Cylinder block and piston 1 Maintenance instructions .................. 170 2 Assembly drawings ....................171 3 Disassembly of the cylinder ................172 4 Inspection of the cylinder .................. 172 5 Disassembly of piston ..................173 6 Inspection of pistons and piston rings ............173 7 Installation of piston rings ................
Page 173: Maintenance Instructions
Maintenance instructions Caution. -The cylinder head lubricating oil goes to the cylinder head through the small oil hole next to the left body AB pin of the engine, make sure the small oil hole next to the left body AB pin is clear before installing the cylinder.
Page 174: Assembly Drawings
Assembly drawings 1、NC450S piston ring assembly. 2、NC450S piston. 3、NC450S piston pin. 4、NC450S piston pin retaining ring. 5、NC450S timing chain assembly (5×134_tooth chain). 6、NC450S chain tensioning plate combination (2#). 7、NC450S chain guide plate combination. 8、Cylinder pin φ6×12. 9、NC450S cylinder block parts (cylinder standard 449_passivated by shot blasting).
Page 175: Disassembly Of The Cylinder
Disassembly of the cylinder 1、Take off the chain guide plate, Chain remove the two cylinder block and guide plate box connecting bolts M6×25, remove the cylinder block. 2、Scrape the remaining gasket on the cylinder surface with a scraper. Inspection of the cylinder 1、Check whether the cylinder block is worn or destroyed.
Page 176: Disassembly Of Piston
Disassembly of piston Remove the piston pin retainer with sharp nose pliers and take off the piston pin and piston. Caution. -The piston pin retainer should not be dropped into the crankcase when removing the retainer. Inspection of pistons and piston rings 1、Remove the piston ring.
Page 177: Installation Of Piston Rings
Installation of piston rings 1, the piston ring groove will be thoroughly cleaned. 2、Fit the piston ring. Caution. 1, in the installation, should prevent the piston and piston ring from being destroyed. 2、When installing the piston ring, the first ring and the second ring should not be installed wrongly, and the side of the first ring and the second ring with the mark should face the top of...
Page 178 Clutch, driving gear, overrunning clutch, oil pump, gearshift mechanism 1 Maintenance instructions ................... 176 2 Water pump cover, right crankcase cover, impeller water pump shaft water seal oil seal removal ......................177 3 Disassembly of clutch, active gear, overclutch, starter gear, right body oil pump ...........................
Page 179 Maintenance instructions Instructions After removing the right crankcase cover, the disassembly, installation and maintenance work concerning the clutch, oil pump and gearshift mechanism can be carried out without removing the engine. Clutch oil pump specifications standard values Maintenance item limit values mm Free spring length Friction plate free thickness 2.95～3.05...
Page 180 Water pump cover removal Remove the water pump cover drain bolt, release the cooling water from the engine at the drain bolt, and remove the water pump cover and the water pump cover gasket when there is no water flowing from the drain bolt.
Page 181 Disassembly Clutch locknut gland bolt 1、Remove the clutch pressure plate bolt and spring, note that when twisting and loosening the clutch pressure plate bolt, it should be twisted and loosened in a cross way in two or three times. 2、Remove the clutch pressure plate and clutch top lever.
Page 182 Disassembly starter motor Remove the fastening screw M6x25 of the starter motor and remove the starter motor. Remove the o-ring [1]. The installation sequence and remove the reverse order. Note: the replacement of a new o-ring and coated with engine oil. Caution.
Page 183 ※Inspection of starter motor [1] [2] Front cover Check whether the oil seal [1] in the front cover is deteriorated, worn or damaged. Turn the inner ring of the bearing [2] with your finger, the bearing should rotate smoothly, and also check whether the outer seat ring fits tightly with the front cover.
Page 184 duplicate Disassembly of duplex gear gear shaft duplicate duplicate gear 1 gear 2 Remove the duplex gear shaft first, then remove the duplex gear one and duplex gear two. shift arm 5-star Disassembly of gearshift parts plate mechanism 1、Remove the five-star plate fastening screw M6×35 and remove the five-star plate.
Page 185 Inspection of right crankcase cover 1, check whether the right crankcase cover crankshaft oil seal is broken, if the oil seal is found to be broken then it needs to be replaced with a new oil seal. Two points should be noted when replacing crankshaft oil seal: 1.
Page 186 3. Check the gap between the clutch cover and the friction plate. Maintenance limit value: 0.6 mm Inspection of clutch cover Check whether the groove on the drum of the outer cover is notched and scarred by the friction of the clutch disc.
Page 187 Assembly of shift mechanism 1、Install the positioning plate combination (4) and flat washer (6), snap the positioning plate spring (3) into the corresponding position of the positioning plate and fasten it with the M6×20 bolt (5). 2, put the five-star plate combination (1) on the shift drum, take a M6 ×...
Page 188 Attention. 1. when installing the oil pump rotor, the marked surface of the inner and outer rotor should face the same direction. 2. tightening torque of the oil pump cover bolts: 7 to 9 N.m. 3. After assembling the cover plate, make sure that the oil pump shaft is flexible in rotation.。...
Page 189 Installation of clutch 1. Install the clutch cover washer (19), needle roller bearing (20), clutch cover (21) and clutch center sleeve washer (22) on the spindle; Note: The clutch needle rollers are evenly coated with engine oil. 2, first clutch center sleeve combination (23), clutch lock nut washer (24) installed on the spindle, clutch lock nut (25) coated with 3 to 4...
Page 190 Magneto, balance driving and driven gear 1 Repair instructions ....................188 2 Disassembly of the left crankcase cover, magneto stator and rotor ... 189 3 Disassembly of balancing master and slave gears, left body oil pump ... 190 4 Inspection of the left crankcase cover, magneto stator and rotor ... 190 5 Balancing master and slave gears Inspection and installation of the left body oil pump ......................
Page 191 Repair instructions The removal and installation of the magneto and balanced master and slave gears described in this section This can be done by simply removing the left crankcase cover without removing the engine. English version...
Page 192 Disassembly of the left crankcase cover Remove the left front cover 8 fastening bolts and remove the left crankcase cover. Disassembly of magneto stator 1、Remove the 2 bolts M5×10 fastening screws of sensing. 2、Remove the 2 bolts M5×40 fastening screws of the stator coil, and then remove the magneto stator combination from the left crankcase cover.
Page 193 Disassembly of balancing master and slave gears 1、Remove the balance active gear lock nut (1) and active gear lock nut washer (2), respectively. 2、Remove the crankshaft timing active sprocket (3) and balance active gear (4). 3、Remove the balance follower gear lock nut (5) and disc washer (6).
Page 194 Balancing master and slave Balance driving gear gears Inspection 1、Check whether the balance master and driven gears are worn or damaged. 2、Balance driven gear buffer spring is broken, if there is broken need to replace the new gear. Inspection of the left body oil pump 1、Check the left body oil pump rotor assembly for wear and damage.
Page 195 (10) and disc washer (11) onto the crankshaft timing active sprocket (9) and balance driven Balance shaft Balance shaft gear combination (7), and put 3 to 4 teeth of driven tooth driving tooth thread fastening adhesive on the balance timing mark timing mark shaft active tooth lock nut M24×1 (12) and balance shaft driven tooth lock nut M16×1...
Page 196 Crankcase, crankshaft, variable speed drive, balance shaft 1 Maintenance instructions ..................194 2 Crankcase Disassembly, Crankshaft/Balance Shaft/Main shaft and Co-Shaft Disassembly........................195 3 Inspection of crankshaft and left and right case bearings ......195 4 Inspection of fork jaws/shift drum/ main and subshaft assembly/oil filter parts, oil screen .......................
Page 197 Maintenance instructions This section introduces the installation and testing of transmission, crankshaft and balancing mechanism. When carrying out the above work, the crankcase should be separated first, and the disassembly of other parts about the engine should be carried out before the crankcase is separated. Work before crankcase separation: -Disassembly of cylinder head -Cylinder/piston disassembly...
Page 198 Crankcase Disassembly 1. Place the left crankcase of the engine upward; 2, remove the 3 bolts M6 M6 x 65 x 70, 3 bolt, six bolt fastening screws M6 x 45, separate left crankcase and right crankcase, remove the two pins. Crankshaft/Balance Shaft/Main shaft and Co- Shaft Disassembly...
Page 199 Measure the thickness of the fork claw. Maintenance limit value: 4.7 mm Check the variable speed drum surface and grooves for wear or damage. Inspection of main and auxiliary shaft components Check whether the gears of the main and auxiliary shaft components have excessive or abnormal wear, and check whether the rings between the gears have deformation and fall off.。...
Page 200 Transmission/crankshaft/balance shaft assembly 1, the balance shaft (1), (2) the crankshaft to the corresponding hole in the left body, 2 (3), the main and auxiliary shaft component to the left the corresponding hole in the body, then fork (4), (5), (7) assembly to the corresponding position, Attention.
Page 201 Fastening torque: 11 ~ 13 N·m. Assembly of oil screen 1、Assembly of the left body oil filter Take 1 oil screen combination (1), apply a small amount of oil on its O-ring and put it into the corresponding oil screen hole. Fit the oil screen cover 0-ring (2) to the oil screen cover, apply an appropriate amount of grease to the inner hole of the oil screen...
Page 202 Front wheel/suspension/steering 1 Overview ....................... 200 2 Troubleshooting ....................201 3 Component Location ..................202 4 Handlebar components ................203 5 Handguard ......................207 6Front wheel ......................209 7 Front shock absorber ..................210 8 Front shock absorber maintenance ............211 English version...
Page 203: Overview
Overview -When servicing the front wheel, front shock and steering column, a special workbench or equivalent is required to support the motorcycle. -Do not operate the brake handle after removing the front and rear wheels. -After installing the front wheel, apply the brake handle to check the brake operation.
Page 204: Troubleshooting
Troubleshooting Hard steering -Low tire pressure -Faulty tires -The steering column adjustment nut is too tight -Worn or damaged steering runout seat -Bent steering column Steering to one side or not straight ahead -Bent axle -Wheel not installed correctly -Wheel bearings worn or damaged -Steering bearing damaged or loose -Damaged frame -Wheel bearing failure...
Page 205: Component Location
Component Location factory edition Handelbar Wheel front shock absorber regular edition Handelbar wheel English front shock version absorber...
Page 206: Handlebar Components
※Handlebar-left（regular edition） Left rear view mirror/clutch handle/left handle switch Disassembly Remove the following parts. - Remove the nut [1] to remove the rearview mirror. - Clutch switch connector [2]. - Two M6x20 inner hexagonal flange bolts [3]. - Clutch handle mount [4]. - Clutch handle [5].
Page 207 ※Handlebar-left（factory edition） Hand guard/clutch handle/left handle switch Disassembly Disassemble the following parts. - Removal of hexagon socket countersunk head screws [1]. - Removal of 2 hexagon socket step screws [2]. - Remove the inner hexagonal socket flange screw [3]. - Remove 2 inner hexagonal socket head flange bolts [1].
Page 208 ※Handelbar（factory edition） Disassembly Disassemble the following parts. - Removal of four internal six-flower external hexagonal flange screws M8x50 [1]. - Remove the directional handle pressure block (ENB bracket) [2]. - Remove the steering handle upper clamp X2 [3]. - Removing the handlebar tube [4]. The installation order is the reverse of the removal order.
Page 209 ※factory edition Handlebar installation installation： Right handlebar: Throttle lever - Handlebar rubber - Start button Clean the sliding surface of the throttle handlebar rubber [1] and throttle turnbuckle [2], and apply grease to the top of the throttle cable and the rolled-up area. Attach the throttle cable [3] to the throttle turnbuckle and install the throttle turnbuckle cable into the throttle lever [4], install the...
Page 210: Handguard
※installation：（regular edition）Handlebar parts Right Handlebar: Right Handlebar Switch - Throttle Turner - Handlebar Rubber Clean the sliding surface of the throttle handlebar rubber [1] and the throttle lever, and apply grease to the top of the throttle cable and the rolled-up area. Connect the throttle cable [2] to the throttle turner and install the throttle turner and cable into the throttle lever [3], then tighten the fuel filler mounting bolts [4].
Page 211 Installation. Left and right handlebars: Handguard (factory edition) Handguard [1] Install the clutch bracket/brake handle bracket, install one end of the handguard bracket at the end of the handlebar tube [2] Handguard [3] Three screws on each of the 2 sides of the left and right handguard brackets are fixed, and then tighten the bolts to the specified torque.
Page 212: 6Front Wheel
※front wheel Note.factory edition vehicles front wheels are removed in the same manner as below. Removal/Installation Remove the following parts. - Removal of 2 brake caliper bolts [1]. - Front axle lock nut [2] and loosen the shock absorbing left and right bottom bucket bolts [3].
Page 213: Front Shock Absorber
※front shock absorber Removing the front shock absorber Disassemble the following components. - Front wheels. - Front brake calipers. - Remove the brake mounting bolts [1] and the front brake caliper [2]. - Remove the front axle lock nut [3] then loosen the left and right shock bottom cylinder lock bolts [4] hold the front wheel and remove the front axle .
Page 214: Front Shock Absorber Maintenance
* Front shock absorber maintenance Place a workbench or equivalent under the engine to lift the front wheels off the ground. Remove the following parts. - Remove the brake mounting bolts [1]. - Front brake caliper [2]. Caution. Do not suspend the brake caliper from the brake hose.
Page 215 Use a special tool to loosen subtracter before cover component tools: lock nut wrench, 50 mm note: do not remove the subtracter inner cavity cover components. Hold front shock absorber rod to loosen the bottom bottom allied board locking bolt [1] to be removed before the shock absorber [2].
Page 216 Compression pipe outside a few times, eliminate the outer tube in [1] from the shock absorber damping oil remove the o-rings [2]. Pour the recommended damping oil into the outer tube [1]. Recommended: oil shock absorber oil (viscosity: 5 w) standard total capacity of 560 ml + 5 high pressure oil storehouse 260 ml 300 ml + 5 + 5 / tube...
Page 217 ※Steering damper Disassembly/Installation Remove the following parts. - Screws [1]; -Remove the steering damper [2]; - Screws [3]; -Remove the steering damper bracket [4]; The order of installation is reversed from the order of removal. Torque. Steering damper mounting screws. 10 N.m (1.0 kgf.m, 7.0 lbf.ft) Steering damper bracket mounting screws.
Page 218 As shown on the left: you can think of each sweep control as the face of a clock, if set at 3 o'clock, the right valve will face the front of the motorcycle and the left valve will face the back of the motorcycle.
Page 219 Rear wheel, suspension 1 Overview ........................217 2 Troubleshooting ...................... 217 3 Component Location ..................... 218 4 Rear wheel ......................... 219 5 Rear flat fork ......................221 6 Rear shock/suspension assembly ..............222 English version...
Page 220 Overview -When repairing the rear wheel and suspension and related parts, you need to support the motorcycle with a professional workbench or equivalent. -Do not operate the brake pedal after removing the rear wheel. -Check the brake operation by depressing the brake pedal after installing the rear wheel.
Page 221 Component Location factory edition Rear wheel Rear fork regular edition Rear wheel English Rear fork version...
Page 222 ※Rear wheel Place a bench or equivalent under the engine to lift the rear wheels off the ground. Disassembly/Installation Remove the following components. - 1 bolt [1]. - Rear wheel speed sensor [2]. - 2 bolts [3]. - Removal of the wheel speed sensor bracket [4].
Page 223 Caution. -When installing the wheels, be careful not to let the calipers fall out of the rear flat fork tabs or damage the brake pads. Install the rear axle from the left side. -Before installing the rear wheel speed sensor [1], wipe the sensor tip and mounting area to remove any foreign material.
Page 224 ※Rear fork Disassembly/Installation Remove the following parts. - Rear brake disc trim [1] factory edition models. - Rear caliper trim [2]. - Rear wheel speed sensor [3] regular edition models. - Disconnect the wheel speed sensor 2P (black) plug. - Remove the screw [1] and the wire clip x2 [2].
Page 225 ※Rear shock absorber/suspension assembly Rear Shock Absorber Remove the following components. - Seat cushion assembly. - Loosen the rear fuel tank assembly attachment nut [1]. - Loosen the lower nut [2] of the rear fuel tank to bracket connection. - Remove the rear muffler and muffler bracket attachment bolts [3] lifting the rear fuel tank assembly.
Page 226 Hydraulic brake system 1 Overview ..........................224 2 Part Location ........................225 3 Brake fluid level check/addition ................226 4 Brake pad inspection and replacement ............... 227 5 Emission of air from hydraulic brake system (ABS) ......... 228 6 ABS Gear Ring Clearance Inspection and Replacement ........ 229 7 Inspection and replacement of brake discs ............
Page 227: Overview
Overview： -This section describes the maintenance of routine brake components of the braking system. -ZF400LS for 2 models of which the civilian version is equipped with ABS, but the brake fluid change procedure is performed differently than the exhaust procedure for competitive vehicles. -Contaminated brake discs or pads can reduce braking efficiency.
Page 228: Part Location
Parts Location Front brake upper pump Front brake caliper Rear brake upper pump Rear brake calipers Note: The four figures above are all factory edition English version...
Page 229: Brake Fluid Level Check/Addition
※Brake fluid level check rear： front： Spilled brake fluid can damage painted, plastic or rubber parts. Caution. Do not mix different types of brake fluids that are incompatible with each other. When filling the reservoir, do not allow foreign objects to enter. ※...
Page 230: Brake Pad Inspection And Replacement
※Brake pad inspection and front： replacement Check the liner. If either liner is worn to 1.0mm (0.04in), both liners must be replaced. Caution. The width of the wear mark [1] is 1.0mm (0.04in) If the brake pads are worn to the service limit, consult your dealer for rear：...
Page 231: Emission Of Air From Hydraulic Brake System (Abs)
※Emission of air from hydraulic brake systems （ABS） The following procedure is only applicable to factory edition -Be sure to vent the brake system air after removing brake related parts. Caution. - Follow the sequence below to bleed the [1] [2] brake system air.
Page 232: Abs Gear Ring Clearance Inspection And Replacement
The following is for regular edition models: Air Venting Operation Procedure (ABS) After the repairer has finished installing ABS, there must be no gas in the line to ensure the ABS works properly. In this case, you need to perform manual air venting operation for ABS with the help of diagnostic instrument.
Page 233: Inspection And Replacement Of Brake Discs
※Check and replace front and rear brake discs Disassembly/Installation Remove the following components. - Remove the cable clamps [1]. - Removal of the brake disc [2]. The front and rear brake discs are installed and removed in the same manner. Apply low strength thread adhesive during installation.
Page 234: Rear Brake Pump/Brake Pedal
※Rear brake pump Drain the brake fluid from the rear brake hydraulic system. Disassembly/Installation Remove the following components. - Remove the brake pipe locking bolts [1]; - Upper and lower sealing washers [2]; - Disconnect the brake hoses to loosen the rear brake upper pump mounting bolts [3].。...
Page 235: Front Brake Calipers
※Front brake caliper Drain the brake fluid from the front brake hydraulic system. Note. factory edition is the same as regular edition disassembly and installation. Disassembly/Installation Remove the following parts. - Wire clips [1]. - 2 bolts [2]. - brake pad locating pin [1]. - brake pads [2].
Page 236: Rear Brake Calipers
※Rear brake caliper Brake caliper trim cover/wheel speed sensor bracket （regular edition） Remove/install the brake fluid in the evacuated rear brake hydraulic system. - Locking bolts [1]. - Rear brake caliper trim cover [2]. - 2 locking bolts [3]. - Wheel speed sensor bracket [4]. Brake caliper decorative cover / brake disc decorative cover （factory edition）...
Page 237 1 Overview ........................235 2 ABS System Function Introduction ..............236 3 Mechanical Schematic ....................237 4 Electrical schematic diagram ................. 237 5 System location ......................239 6 ABS Master Pump ...................... 240 7 Check Diagnostic Process and Troubleshooting ..........242 8 Fault Code Information Table ................
Page 238: Overview
Overview： -This section covers repair of the anti-lock braking system (ABS). For other repairs to the brake system (conventional braking), see the section on hydraulic brakes. -The ABS control unit is integrated into the regulator. Do not disassemble the ABS regulator. When the ABS regulator fails, the ABS assembly will be replaced.
Page 239: Abs System Function Introduction
ABS system function introduction System Description. The ABS assembly consists of a hydraulic control unit (HCU), an electronic control unit (ECU) and a motor, mounted on the frame with a wheel speed sensor on the front and rear wheels respectively. The function of the ABS warning light: to indicate whether the ABS is working properly If the ABS is malfunctioning, the warning light will come on to warn the driver.
Page 240: Mechanical Schematic
Mechanical schematics English version...
Page 241 Electrical schematic English version...
Page 242: System Location
System Location regular edition： pump Front brake, rear brake, ABS ABS ring gear ring gear English version...
Page 243: Abs Master Pump
※ABS master pump Drain the brake fluid from the brake hydraulic system. Disconnect the negative (-) battery connection. Disassemble the following components. - Disconnect the ABS regulator 18P (black) connector [1] - Remove the brake fluid line locking bolt and sealing washer and disconnect the brake fluid line from the master cylinder.
Page 244 ※Wheel speed sensor Air gap inspection front rear Use a crane or equivalent to securely support the motorcycle and lift the wheel off the ground. Slowly turn the wheel and measure the clearance (air gap) between the sensor and the gear ring at multiple points. Must be within specifications.
Page 245: Check Diagnostic Process And Troubleshooting
Check Diagnostic Process and Troubleshooting （1）. How to use the diagnostic meter 1. Connect the diagnostic instrument to the diagnostic interface. 2.Turn on the ignition switch. 3. Read fault-related information (fault codes, freeze frames, etc.); check the repair manual to confirm the faulty part and type; develop a repair plan based on fault-related information.
Page 246: Fault Code Information Table
（3）.Fault code information English version...
Page 247: Fault Code Corresponding Treatment Measures
（4）.Fault code corresponding measures English version...
Page 248 Note: The C0060, C0061, and C0062 faults will not occur for products that are configured in software without a brake signal. English version...
Page 249: Circuit Troubleshooting
※Circuit Check 1. ABS plug check Turn off the ignition switch Remove the ABS regulator cover. Turn the locking lever [1] to this side while pressing the locking tab [2] to release it. Make sure the lock lever is turned all the way and disconnect the ABS regulator 18P (black) connector [3].
Page 250: Abs Indicator Troubleshooting
※ABS Indicator Troubleshooting ABS indicator light does not light up (when ignition switch is on) Note: before you start to check, and check the initial combination meter operation. 1.Indicator running check Turn off the ignition switch Disconnect the ABS regulator 18P (black) connector.
Page 251 3.Fuse inspection Remove the following components. -Remove the seat cushion by pulling down the seat cushion pull lock Remove the fuse box cover from the fuse box. Check for a blown ABS main fuse. Is the fuse blown? YES -Go to step 4 NO -Go to step 5 4.Power input line short circuit check With the ABS main fuse (15A/20A)
Page 252 Electrical parts 1 Power supply system..................250 2 Switchs........................ 254 3 Lights ........................261 4 Other parts ......................264 English version...
Page 253 1.Power supply system Charging circuit diagram magneto regulator Connecting load (factory edition) battery ※magneto Magneto coil resistance Measure the resistance between the magneto stator coils, the resistance value is within the specified range, it means the magneto is good; magneto otherwise, it means abnormal, replace immediately.
Page 254 ※rectifier After the engine runs, when the battery is fully charged at 5000r/min, use a multimeter to measure the voltage between 13.5V and 15V at both ends of the red, red, white, and green lines. If the voltage is not within Connect magneto input this range, replace the rectifier regulator...
Page 255 ※Check and replace the battery 1. Before installing the battery, if the electrode is found to be dirty, please wipe it clean before installing it, otherwise it may fail to function due to poor contact. 2. If the battery is deformed, abnormally hot, smoking and other abnormal phenomena occur during use, please stop using it immediately and go to the special maintenance store of Kaiyue Motorcycle for investigation in time.
Page 256 Warnings and precautions for battery use 1. It is strictly forbidden to invade the battery into seawater or water, avoid drenching; when not in use for a long time, it should be placed in a cool and dry environment. 2. It is forbidden to use or leave the battery next to high temperature sources, such as open flame, heater.
Page 257 2.Switchs ※Right combination switch Outline drawing （regular edition） and pin Disconnect the plug of the right hand handle switch harness linked to the main cable and check the action on/off of each switch. [1] Flame-out self-locking button. ① The engine can be started only when the switch is in the "...
Page 258 ※brake switch The brake switch working status is judged by the lighting of the brake light. 1: front brake handle pinch: brake light on. 2: front brake handle release: brake light off. 3: depress the rear brake pedal: brake light 4: release the rear brake pedal: brake light off.
Page 259 ※Turn signal flasher (flasher) Attention. The flasher is equipped with wire break alarm prompt function and load overload protection function. Removal/Installation - Turn off the ignition switch. - Removing the seat cushion assembly. - Removal of the flasher. Flash profile and pins Install in reverse order of disassembly.
Page 260 ※Fan and temperature control switch Fan motor check. Battery voltage 12V motor running at full speed, amperage meter current does not exceed 3A, if the motor does not rotate or the current exceeds the specified then replace the fan motor. As shown above.
Page 261 ※starting relay Starting Relay Outline Load DC12V voltage on the contacts of both Drawing ends of the control circuit coil of the starter relay, then use a multimeter to measure whether the B+ and M contacts are connected. If the relay contacts emit a ticking sound and the multimeter emits a continuous ticking sound, it means that the two contacts are connected: the opposite means that they are not connected: when...
Page 262 P1：headlamp relay outline drawing and electrical wiring diagram. p2,p3：The outline diagram and electrical wiring diagram of the vehicle relay. p3：Wiring diagram for factory edition relay. p4：regular edition relay wiring diagram. English version...
Page 263 ※Fuse To avoid short circuit, be sure to set the main power switch to "OFF" first when checking or replacing the fuse. 2. Check. - Fuse a. Connect a digital multimeter bit to the fuse and check for conduction. b. If it is not conducting, replace the fuse.
Page 264 3.Lights ※Headlight assembly and headlight control module factory edition Headlamp The headlights come on outline drawing automatically after starting the vehicle and turn off automatically after the engine is turned off. regular edition Headlamp The headlights do not light up after outline drawing starting the vehicle or the high and low beam cannot switch fault.
Page 265 ※Rear position light, tail light (factory edition) P1：The rear position light is at position [1] and the rear tail light is at [2]. When the vehicle is in starting state. 1: the rear position light comes on after the vehicle starts. 2: After the vehicle is turned off, the rear position light goes off.
Page 266 ※Front and rear turn signals, rear taillights, license plate lights (regular edition) Turn on the ignition switch. 1: Press the left and right turn signal buttons respectively, the lights come 2: Press the turn signal centering button, the light goes out. 3: the license plate light comes on automatically.
Page 267 4.Others parts ※meter (regular edition) Display check: When the ignition lock switch is turned to " " (on), the instrument is energized to play the power-on animation, followed by a self-test, and all function modules and symbols are displayed; if the display is missing during the self-test, please Above is the outline of the instrument refer it to an Escalade locomotive...
Page 268 ※Oil level sensor (regular edition) Oil level sensor outline diagram Convert the fuel liquid height signal into a standard electrical signal and output it to the indicator light. P2：wiring diagram of oil level sensor and TFT meter. TFT meter oil level displays parameters ＜...
Page 269 ※Road book box, speedometer, and directionometer (factory edition) Display check. Long press the start button " " to the vehicle start state when the instrument is energized, if the instrument is not on, you can wake up the instrument by short press the instrument button. Such as the left figure 1 position [1] for the speedometer, [2] for the heading gauge, the [3] the main body of the pull road book box.
Page 270 ※Left-handle switch (factory edition) p1: Position [1] is the control button of the road book box,[2] is the combination button of the speedometer,[3] near and far light switch button,[4] horn button, and [5] flame out button. [1] : The thumb button is used to move forward and backward to control the rolling of paper books in the book box.
Page 271 ※meter light (factory edition) P1： [1] is the engine fault indicator light. This light comes on when there is a fault in the EFI system (after the engine is powered on, this light is lit. After normal start, this fault light goes off as normal); [2].
Page 272 ※Oil level sensor Oil level sensor (factory edition) outline drawing Convert the fuel liquid height signal into a standard electrical signal and output it to the indicator light. ground power signal ※Oil level sensor Disassembly/Installation Remove the following components. - Disconnect the sensor plug. - Remove 1 countersunk hexagonal head bolt at position [1] P2.
Page 273 ※Horn Unplug the harness connector on the horn [1] and connect it to the 12V power supply, the normal sound of the horn means normal, otherwise, it needs to be replaced. ※Clutch switch (regular edition) When in gear position, pinch the clutch handle, put away the side support, you can press the start button, realize the vehicle start.
Page 274 ※Gear sensor Check: Disconnect the plug that connects the gear sensor harness to the main cable, check the gear sensor harness connector, and check the sensor harness connection status. Removal/Installation Remove the following components. - Small sprocket trim cover. - Removal of the screw at position [1]. -The gear sensor [2] can be removed.
Page 275 Three-in-one sensor magneto oxygen sensor H1 intake temperature ignition coil J3 5V power G1 throttle position Rectifier Heating signal 1 K1:intake pressure injector J1 Sensor ground wire Oil pump Oil level Sensor temperature controlled switch fan-left fan-right right switch stepping motor Lateral Tilt Sensor Trigger coil color...
Page 276 Three-in-one sensor magneto Rectifier Ignition coil oxygen sensor Heating signal 1 Injector Fan-left Fan-right color blue black yellow Ignition lock temperature controlled switch function yellow white red switch-right yellow yellow green white yellow black black yellow yellow white purple 　 orange 　...

Kove 450 Rally Maintenance Manual

Basic Information

Regular Maintenance and Adjustment

Table of Contents

Table of Contents

Cooling System

Engine Removal/Installation

Table of Contents

Cylinder Block and Piston

Front Wheel/Suspension/Steering

Hydraulic Brake System

Table of Contents

Quick Links

Chapters

Troubleshooting

Need help?

Questions and answers

Related Manuals for Kove 450 Rally

Summary of Contents for Kove 450 Rally

Table of Contents