Benelli Tornado TNT600 Owner's Manual

1

OWNER’S MANUAL 2013

2

3

CONTENTS

PRE FACE 4
IMPORTANT NOTES 5
SPECIAL ATTENTION 6
SAFETY NOTES 7

SAFETY RIDING RULES 7
PROTECTIVE CLOTHES 8
PROTECTIVE HELMETS 8
NOTES FOR RIDING IN R AINY DAYS 8

SERIAL NUMBER 9

VEHICLE IDENTIFICATIONS NUMBER 9
ENGINE NUMBER: 9

CONFIGURATION OF PARTS 10

BODY PARTS 10
METER PANEL 13

OPERATION PROCEDURES 15

POWER LOCK 15
LEFT HANDLE 16
RIGHT HANDLE 18
FUEL TANK 20
GEAR SHIF TING PEDAL LEVER 21
REAR BRAKE PEDAL 22
SIDE STAND 23
REAR SUSPENSION PRELOAD 24

USAGE INSTRUC TION 25

FUEL 25
ENGINE OIL 26
BREAKING IN 26
CHECK BEFORE RIDING 27

DRIVING OF MOTORCYCLE 29

STA RTING 30
USING GEAR SHIF TING MECHANISM 30
DRIVING ON THE SLOPE 30
USING BRAKE AND STOPPING 30

INSPECTION AND MAINTENANCE 32

MAINTENANCE SCHEDULE 32
ENGINE OIL 34
SPARK PLUG 35
ADJUSTMENT OF ACCELERATOR CABLE WIRE 36
ADJUSTMENT OF CLUTCH 37
ADJUSTMENT OF IDLING SPEED 38
THROTTLE BODY 39
DRIVE CHAIN 40
BRAKE 44
TI RE 47
OIL ACCUMULATION PIPE 48
SERVICING OF AIR FILTER 49
CATALYTIC CONVERTER 50
CANISTER 51
FUEL INJEC TOR AND OIL PASSAGE 51
LUBRICATION OF PARTS 52
STOR AGE BATTERY 53

STORAGE G UIDANCE 58
SPECIFICATIONS AND TECHNICAL PARAMETERS 60

4

Thanks for choosing TNT600 EFI two-wheeled motorcycle, which is combined with the national
and international advanced technologies and would bring you a happy and safe riding
experience.

Motorcycle driving is one of the most exciting sports events. Please fully understand and abide
by the rules and requirements stated in this manual before driving.

This instruction manual covers the maintenance procedures, which would ensures the maximum
performances and highest durability of your motorcycle service.

Benelli is equipped with professional technical service personnel and department, which is able
to provide you with highest quality technical services.

Insisting in the principle of “customer rst”, Benelli makes great eorts to develop the products
quality and performances so that the appearances and structures are always being innovated
with advance structure.

The picture information in this Manual is only for references, the actual style may dier.

PREFACE

5

1. Rider and passenger capacity.

This motorcycle is designed only for two riders.

2. Road surface for riding.

This motorcycle is suitable for highway riding.

3. Please carefully read this user manual. Careful and proper riding running-in will ensure the
stable and smooth running of your motorcycle.

Please pay special attention on the following:-

IMPORTANT NOTES

Note : This is for the maintenance or more important events explanations.

Caution : This is for the operating specications of the motorcycle.

Warning : This is for the important procedures that may endanger safety of the

rider or would bring injuries if ignored.

The User Instruction should be considered as a permanent manual for the motorcycle. Please
give it to the new owner if you transfer the motorcycle.

No copy or reproduction of any part in this manual without written approval from Benelli.

6

• Fuse compartment is next to the storage battery.

• Fuse specication: 20A for main power source fuse and 15A for ECU system fuse.

• Burnt fuse is generally caused by a fault in the electrical circuit of the motorcycle. It is

recommended to send the motorcycle to our Authorised Service Center to have it check
and repair.

SPECIAL ATTENTION

The motorcycle must be equipped with a specify fuse only to avoid any serious damage or accident.

Always ensure the positive and negative lead of the battery are properly install. (Never install in reverse
order). When reversely installed please check the condition of the fuse.
Before replace the fuse, please turn the key to “ “ to prevent the shor t circuit.

7

1. Have a complete inspection before starting the engine so as to prevent possible
accidents or damages of spare parts.

2. Never lend it to any people without a driving license.

3. To avoid damages by other motor vehicles, the rider shall try his/her best to be visible at
all time. Including:

a) Wearing bright clothes;
b) Keeping away from other motor vehicles;

4. Obey the trac rules strictly and do not jump queues;

5. Speeding is one the key reasons of the accidents. So keep the speed within the limit.

6. Turn on the signal lamp so as to be noticed by others when tuning the corner or changing
a drive lane.

7. Ride carefully on a crossway, passageway of a parking lot and on highway.

8. Any modication disassembly of the spare parts would aect the safety driving and
maintenance.

9. The installation of the accessories shall not aect the safety driving and operation
performances of the motorcycle. The overloading of the electrical systems would easily
cause damage.

SAFETY NOTES

SAFETY RIDING RULES

8

1. In order to assure personal safety, the rider should wear protective helmet, protective
glasses, driving boots, gloves and protective clothes. The passenger should also wear the
protective helmet.

2. The exhaust system will be hot during running and still be hot for a while after the engine
is stopped. Never touch the exhaust system when it is hot. Please wear the clothes that
can fully cover your feet.

3. Please do not wear loose clothes that may be trapped by the control lever, foot pedal
starting equipment, pedals or wheels during driving.

Protective helmet that conforms to the safety quality standard is the primary protective gear in
driving. The most serious accident is head injury. Please wear protective helmet and protective
glasses as well.

Pay special attention in rainy days as the road is wet and the brake distance is two times as of
the clear days. Avoid the signs for paints, manhole cover and greasy dirty grounds. Be careful of
railway crossing, railings and bridges. Slow down when the road condition is not clear.

PROTECTIVE CLOTHES

PROTECTIVE HELMETS

NOTES FOR RIDING IN RAINY DAYS

9

Vehicle Identication Number and the Serial Number are used for the registration of the
motorcycle, including all necessary back up service.

Remember the numbers for the possible uses in the future.

1. The frame number is printed in the right side of head tube

2. Product nameplate is riveted on the head tube.

3. The engine number is printed on lower part of the right case of engine crank case.

SERIAL NUMBER

VEHICLE IDENTIFICATIONS NUMBER VIN:

ENGINE NUMBER:

Please write down the numbers for your references;

1

2

3

10

CONFIGURATION OF PARTS

BODY PARTS

1. Clutch Lever Left

2. Left Handle Switch

3. Clutch Lever

4. Fuel Tank Lock

5. Meter

1

2

3

4

5

6

7
8

9

10

6. Right Handle Switch

7. Right Side Mirror

8. Front Brake Lever

9. Throttle

10. Fuel Tan k

11

1. Rear Brake

2. Rear Foot Pedal

3. Front Foot Pedal

4. Rear Brake Pedal

5. Fuel Oil Observation Hole Side Stand

6. Front Brake

1 2 3 4 5 6

12

1. Front Brake

2. Gear Shift Pedal Lever

3. Front Foot Pedal

4. Side Stand

5. Rear Foot Pedal

1 2 3 4 5

13

Left Signal Lamp Indicator
Light

Right Signal Lamp Indicator
Light

High Beam Indicator Light

Engine Lubricant

Neutral Gear Indicator Light

Function Button

Fuel Oil Level Indicator

Tachometer Odometer

Temperature

Speedometer

Time Display

x1000rpm

FI

TRIP

km/h

km

C

CLOCK

E

F

N

METER PANEL

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1. Left signal lamp indicator light

When the turn signal lamp is turning left, the left

steering lamp indicator light will ash.

2. Right signal lamp indicator light

When the turn signal lamp is turning right, the right

signal lamp indicator light will ash.

3. High beam indicator light

When the head lamp high beam is on, the high beam

indicator light will be on.

4. Engine lubricant

5. Neutral gear indicator light

When the transmission is on neutral position, the

neutral gear indicator light will be on.

6. Function button

7. Tachometer

Tachometer indicates the revolution of engine.

8. Temperature

9. Speedometer

Speedometer indicates the driving speed, km/hour.

10. Time display

11. Fuel oil level indicator

12. Odometer

TRIP or ODO function on the odometer can be chosen

as required.

TRIP: An odometer than can be zero cleared, recording

the driving mileage within a period. On the state of
TRIP, please press ADJUST button three times to clear.

ODO: recording all the driving mileage, measured in

km. Odometer keeps records of the driving mileages
in kilometers.

15

When the key turns to “ ”position, the power gets through and the engine starts to run. The
key can not be taken out.
When the key turns to “ ”position, the power cuts o, and the engine can not run. The key
can be taken out.
(Park) position: when the vehicle parks at roadside at night, the key turns to “ ” position,
the key can be taken out now, the rear lamp (parking lamp) will be kept on.
(Lock) position: turn the key counter-clockwise to “ ” position, the lock will extend out the
lock core to lock.

OPERATION PROCEDURES

POWER LOCK

Lock the turn direction and take out the key to prevent from being stolen. Turn and conrm the lock. Do not
park in the place holding up the trac.

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LEFT HANDLE

Clutch Handle

Headlamp High-Low Beam

Turn Signal Lamp Switch

Horn

17

Clutch handle

When starting the engine or shifting the gear, operate the clutch handle to cut o the driving
of rear wheel.

Horn button

Pressing the horn button, the horn will make sound.

Headlamp high-low beams switch

Press the headlamp high -low beams switch to position, the headlamp high beam will be on
and high beam indicator light in the instrument panel lights up too;
Press the switch to “ ”position, the headlamp low beam will be on. Use low beam light when
driving in the downtown or in front of vehicles so as not to inuence the vision of other people.

Turn signal lamp switch

Press the left turn signal lamp switch , the left turn signal light will ash. At the same time,
the green turn indicator light in the instrument panel will ash too. Turn the turn signal lamp
switch to the middle position to cancel the turn signal.

Lighten up the turn signal lamp when making a turn or changing lanes. Turn o the turn signal lamp in time
after making a turn so as not to aect the normal driving of other vehicles and avoid accidents.

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RIGHT HANDLE

Front Brake Handle

Hazard Warning Lamp Button

Engine O Switch

Accelerator Control Handle

Electric Starting Switch

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Engine o switch

When the switch is pressing at position, the power of the complete vehicle will be on and the
engine can start.
When the switch is pressing at position the power of the complete vehicle will be cut
o and the engine can not start.

Hazard warning lamp button

Electric starting switch

Press the electric starting switch, the electric motor will run and the engine can start.

Accelerator control handle

The accelerator control handle is used to control the speed of engine. Turn the handle facing
the driver to accelerate, turn the handle reversely to decelerate.

Front brake handle

Grasp the right brake handle slowly to front brake.

20

Insert the fuel tank key and turn the key clockwise to open the fuel tank cover, the fuel tank
cover can be opened with the key. Guide pin against the fuel tank and then press down to
close the fuel tank cover, take it out until the locking sound is heard.

FUEL TANK

The fuel tank can not be over-lled. Do not spray the fuel onto the hot engine, which may be dangerous.
Please stop the engine when lling, and turn the ignition key to“ ” (o ) position.
Do not forget to lock the fuel tank cover after lling to prevent the fuel evaporating into the air, which will
waste the energy and pollute the environment.
No smoking or naked lights when lling.
If the fuel overow and enter into the canister or other parts, please see your authorised Ser vice Center
soon to clean or replace the canister, because too much fuel entering into the canister will cause the active
carbon be ineective prematurely.
Please check the smoothness of the down nozzle at the fuel tank cover regularly to assure the smooth
draining and prevent the external water entering into inner cavity of fuel tank.

21

This motorcycle comes with the constant mesh six-speed non cyclical gear shifting, the
operation is shown as in the gure. The neutral position is between the low-speed gear and
two-speed gear, step down the gear shifting lever from the neutral position to select the

low-speed gear; use the tiptoe to move the gear shifting pedal upward (or use the heel to
step down) to change into the next high gear; use the tiptoe to step the gear shifting lever to
change into the next low gear.

GEAR SHIFTING PEDAL LEVER

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Step down the rear brake pedal (as shown in the Figure) to put into gear of rear
brake, when operating the rear brake, the brake lamp will be on.

REAR BRAKE PEDAL

23

The kick stand is located at the left side of the vehicle, please use your foot to shift the stand
into proper position when stopping.

SIDE STAND

Do not put the vehicle at the declinational slope, otherwise the vehicle may over turn.

24

The spring on the rear shock absorber can be adjusted to bear dierent situations and road
conditions as required by the driver. There are ve positions for adjustment available. Use the
kick stand to support the motorcycle properly and turn the spring adjusting
ring to the needed position.

REAR SUSPENSION PRELOAD

25

It is better to use lead-freefuel or low-lead fuel. The octane value of the fuel should be above

90. If the engine makes slight knocking sound, fuel of common grade may be used, which
should be replaced.

USAGE INSTRUCTION

Using lead-free fuel or low-lead fuel can extend the service life of the spark plug.

When the transmission is on neutral position, the indicator light will be on, the rider should loose the clutch
lever slowly to conrm if the transmission is at the neutral position.

FUEL

26

Please use the high clarity and high quality engine oil which conforms to or above SF level.
Always insist on recommended fully synthetic motorcycle engine oil.

The engine of the new motorcycle shall not be over-run and theRPM speed on any gear shall
not exceed 80% of its maximum rotating speed during the rst 1,000km driving period; do not
operate the throttle when it is fully open; at the same time, change the gear appropriately to
prevent the engine being over-pressurized. Careful operation of the new motorcycle during
the breaking in period will be greatly useful to extend the service life of the motorcycle.

Special attention:

In the rst 500km of breaking in, is important to replace the engine oil and used only
recommended fully synthetic motorcycle engine oil as specify.

ENGINE OIL

BREAKING IN

27

Please check the following items before driving. The importance of these checks shall not be
ignored.

Scope of Checking

Handle

Wheel

Fuel Storage

Light

Brake

Focus of Checking

1) Stable

2) Revolve smoothly

3) No axial oat and loose

1) proper air pressure

2) proper lug depth

3) no ssure or cut

1) Enough fuel storage to drive the planned distance

1) Operate all the lamps-headlamp,rearlamp, brake lamp
instrument-panel lamp and steering lamp etc.

1) proper clearance between the handle and brake pedal

2) no feeling of braking ineective braking

3) no oil leaking

CHECK BEFORE RIDING

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Indicator Light

Horn & Brake Switch

Engine Oil

Accelerator

Clutch

Driving Chain

Storage Battery

Electrolyte

High beam indicator light, gear indicator light, turn signal
indicator light

Function normally.

The oil level is proper.

1) Proper accelerator cable clearance

2) Smooth fueling and quick fuel cut-o

1) Proper cable wire clearance.

2) Smooth operation.

1) Proper degree of tightness.

2) Properly lubricating.

Check the electrolyte level and add the electrolyte as needed.

29

STARTING OF ENGINE

DRIVING OF MOTORCYCLE

Turn the power lock clockwise to the contact of “ ”position, if the transmission is on neutral
position, the neutral position indicator light will be on.

Start the engine by electric starting, ECU will provide the fuel necessary to start the engine in
accordance with the ambient temperature and the engine condition.

Grasp the clutch handle and start the engine when the transmission is on the neutral position.

Do not over-run the engine when not driving, for it will make the engine overheated and may damage the
internal parts of the engine.

Do not start engine in poorly ventilated places. Do not leave the motorcycle unattended when the engine
is on.

30

STARTI NG

USING GEAR SHIFTING MECHANISM

DRIVING ON THE SLOPE

USING BRAKE AND STOPPING

Grasp the clutch handle for a short moment, then step down the speed shifting lever to put
into rst gear. Turn the accelerator control handle facing the driver, at the same time, loose the
clutch handle slowly and stably, now the motorcycle will move forward.

The gear shifting mechanism can ensure the stable running of the engine under normal
operation range. The rider shall choose the optimum gear shifting under general conditions.
The rider should decelerate and make the engine to run within the normal running range.

When climbing steep slope, the motorcycle will begin to decelerate and seem to be
underpowered, the rider should change into the lower gear, then the engine can operate
within its normal power range. Please shift the gear quickly to prevent the motorcycle to lose
speed.
When on downhill, please shift the engine into lower gear for the convenience of braking. Do
not make the rotating speed of the engine too high.

Use the front and rear brake evenly at the same time. Lower the gear to slow down.(Apply the
engine brake).
Press the clutch lever against the control handle (cut-o position) before the motorcycle stops
and shift into neutral position.

31

The inexperienced rider often uses the rear brake only, which will accelerate the wearing of brake and make
the braking distance too long.

The motorcycle should be placed at solid and at ground. Do not park the motorcycle at the
place which will block the trac. If the rider has to place the motorcycle at the slope with a kick
stand, please put the motorcycle into rst gear to prevent skidding and shift the gear back into
the neutral position before starting the engine.
Turn the ignition switch to o “ ” position to stop the engine and take down the ignition
key from the switch.

Using only the front brake or the rear brake is dangerous, which will cause slid or lose of control. Use the
brake carefully and slightly when riding on the wet highroads, slippery road surface and all the roads with a
curve. It is very dangerous to use the brake to stop the motorcycle suddenly.

32

The following table is the periodic service interval. After each time limit, inspection,
verication, lubricating and stipulated maintenance must be carried out in accordance with the
stated instructions. The steering gear system, support and wheel system are key components,
which require carful maintenance of specialized technical personnel. For the sake of safety, we
recommend you to contact your authorised Service Centre to perform these job.

I - Inspection, cleaning, adjustment, lubricating or replacement
C - Cleaning
R - Replacement
A - Adjustment
L - Lubricating

INSPECTION AND MAINTENANCE

MAINTENANCE SCHEDULE

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* means items must be repaired by qualify technician
** means ite ms that to be repaire d by authorised de alers.
Note:

1. More inspec tion and mainten ance if riding on the d usty areas.

2. If the odo meter reading e xceeds this value, re peat the mileage s shown in the odom eter to continue the in spection.

3. If often d riving on bad roa d conditions such as r ough and uneven ro ad surface, fre quent maintenanc e should be given to ma intain the good p erformance of t he motorcycle.

MAINTENANCE
ITEMS

Fuel Passage*

*

*

*

**

*

*

*

**

*

**

*

I I I

Spark Plug I R I 35

Air Throttle Operation I I I 36

Engine Oil R at 1st 500KM - 1000KM and then every 5000KM

Per 1000KM: I, L, A

Oil Filter C C C

Valve Clearance I I I I

34

Air Filter Note 1 C C C 49

Oil Filter Screen

Wearing of Brake Disc

Suspension System

Drive Chain

Clutch Equipment

Brake Switch

Wheel/Wheel Rim

Note 3

Note 3

C

I

I

C

I

I

I

I

I

C

I

I

I

I

I

C

I

I

I

I

I

45

40

37

Engine Idle Speed

Brake System

Nut Bolt Fastener

Storage Battery

Stay Bar

Light Adjustment of Headlamp

Steering Gear

Note 3

Note 3

I

I, A

I

I

I

I, A

I

I

I

I

I, A

I

I

I

I

I

I, A

I

I

I

I

38

44

53

CYCLE

MAINTENANCE MILEAGE

COMMENT 1000KM 8000KM4000KM 12000KM

REFERENCED

PAGE

ODOMETER READING (NOTE2)

34

Please check the engine oil level before staring the engine. When checking the oil level, place
the motorcycle on vertical at ground and use the oil gauge to watch if the oil level is within
the scale range. When the oil level is below the lower scale mark, please open the upper oil
ller cap and add the oil to the upper scale mark.

ENGINE OIL

Replacing the engine oil when the temperature of the engine is warmed. Fix the frame with the central
support bar to ensure the engine oil is drained quickly and completely.

35

In the initial 1000km driving and every 4000km interval, use the small metal wire or spark plug
cleaner to clear the carbon deposit on it. Use the spark plug gap-measuring plate to readjust
the spark plug electrode gap and keep it within 0.6-0.7mm. Replace the spark plug after every
8000km driving.

SPARK PLUG

The spark plug shouldn’t be screwed too tight to make the thread damage in case of damaging the thread of
cylinder cover. Don’t let any other subjects to fall into the engine when disassembling the spark plug.

36

1. Check if the throttle manually-operated pull button revolves smoothly from the fully
open position to fully closed position.

2. Measure the free play of throttle control pull button at the air throttlemanually-operated
pull button ange. The standard free play should be 10°~15°.

Unscrew the locking nut (1) and turn the regulator (2) to adjust the free stroke.

ADJUSTMENT OF ACCELERATOR CABLE WIRE

37

The free play of the clutch takes the endpoint position of clutch lever as standard before the
loosing of clutch, the free play should be 10—20mm. If the free play is improper, please adjust
it in accordance with the following procedures:

1. Loose the locking nut

2. Screw in or screw out the adjusting screw, adjusting nut, making the free play of clutch
meet with the specied requirement.

3. Screw up the locking nut.

ADJUSTMENT OF CLUTCH

38

The engine should be at normal operation temperature to accurately adjust the idling speed.

1. Place the motorcycle aat vertical position and start the engine to heat-up.

2. Use the throttle stop screw to adjust the idling speed to 1400-1600r/min

Turn the adjusting screw clockwise to the decrease the rotating speed, while screw the

adjusting screw counter clockwise to increase the rotating speed. Please do not over­screw the adjusting screw counter clockwise, otherwise the idling speed will decrease
instead and be unstable.

3. Please cut o the engine after adjustment, and restart after three 3 seconds, after two
minutes’ stable operation, please conrm the idling running again.

Start the engine to warm up it during the idling. After that, close the accelerator and

adjust the idling screw knob to keep the rotating speed of engine in the lowest stable
level (between 1400-1600r/min). The idling screw is located at the right side of connecting
port between throttle valve and air lter.

ADJUSTMENT OF IDLING SPEED

39

The idling speed of the motorcycle will decrease because of the throttle body pollution; please
clean the throttle body after each 5000km’s driving.

Please disconnect the negative electrode lead connection of battery and disconnect the
sensor connector installed on the throttle when cleaning the throttle body; remove the
accelerator stay and the hose connected with air lter and intake manifold, then remove the
throttle body.

Open the cover at the bottom of throttle body, spray the detergents onto the inner wall of
throttle body and brush away the dirt and carbon deposit.

After cleaning, please operate in reverse order to install the throttle body and ensure the
proper installation of all parts, then start the engine.

THROTTLE BODY

Do not let the impurities block the bypass airway.

40

The service life of drive chain depends on the proper lubrication and adjustment. The improper
maintenance many cause the abnormal early wear of the drive chain and chain wheel. If under
extreme sevior operating conditions, frequent maintenance must be given.

Adjustment of drive chain:

After each 1000km’s driving, please adjust the drive chain and make the chain free play be
10 - 20mm. The chain needs to be adjusted frequently according to your driving conditions.

DRIVE CHAIN

The recommendation above is the maximum adjustment time interval, actually, the chain should be
checked and adjusted before each riding.

Free play

41

Please adjust the chain in accordance with the following procedures:

1. Use the central support to lift up the motorcycle.

2. Loose the rear axle nut.

3. Loose the locking nut.

4. Turn the adjusting bolt to the right or to the left to adjust the tightness of the chain. The
front and rear chain wheel should be kept aligned when adjusting the chain. There are
reference marks on the swinging arm and each chain adjustor to help you to carry out
the adjustment. These reference marks can be aligned mutually and be the reference
from one end to the other end. After aligning and adjusting the tightness of chain to
10—20mm, please retighten the rear axle nut to carry out the nal check.

42

After replacing the new chain, please check if the two chain wheels are worn. Please replace if necessar y.

The chain connector is clipped between the open end, please install against the moving direction

Chain Connector

43

Please check the following conditions of the chain regularly:

1. Loose pin

2. Damaged idler wheel

3. Dried and rusted chain link

4. Knotted or seized chain link

5. Excessive damage

6. Adjustment of loose chain

Please check the following conditions of the chain wheel:

1. Over-worn wheel tooth

2. Broken or damaged wheel tooth

3. Loose chain wheel retaining nut.

Lubrication of Drive Chain

Apply chain lube or soak all the chain links and make the lubricant go through the chain plate,
pin, bushing and roller.

44

Both the front and rear wheel of the motorcycle is tted with disc brake. The proper brake
operation is very important to the safe driving. Please remember to check the braking system
regularly, and this check should be carried out by qualied distributors.

Adjustment of Brake

(1) The free play of front brake handle ends should be 10-20mm.
(2)Measure the moving distance of brake pedal before and after the brake works. The free play
should be 20-30mm.

BRAKE

10-20mm

45

Brake Disc

The essential of checking the front wheel brake disc is to check if the disc is worn to the limit
mark. Please replace it with a new brake disc if worn to this mark.

Brake uid

If the liquid level is lower than the LOWER mark, the recommended brake uid should be
added. Adding brake uid is one of the important items in regular maintenance.

46

Braking system

Please check the following conditions of the braking system every day:
(1) Check if there is leakage of the front and rear wheel braking system.
(2) The brake lever and the brake pedal should have a certain amount of support
resistance.
(3) Check the wearing condition of the brake pad. The essential of checking brake pad
is to watch if the pad is worn. If exceeds the limit line, the two brake pad should be
replaced together.

The motorcycle use DOT3 or DOT4 brake uid. Take care not to allow brake uid to get into with paint
surface or plastic surface because these surfaces will be corroded.

If the braking system or brake disc of your motorcycle needs to be repaired, we recommend that the repair
should be carried out by authorised distributors. They are equipped with complete tools and procient
skills, which will ensure the safest and most economic work. After replacing the new wheel brake disc,
please pick and place the brake lever several times to fully extend the brake disc and restore the normal
support resistance of lever.

47

Please check the tire pressure when the tires are “cold” before driving

Please do not try to repair the damaged tire. The wheel balancing and tire reliability may become worse.
The improper tire ination will cause abnormal tread wearing and threaten the safety. The insucient tire
ination may cause tire skidding. Driving motorcycle when the tires are over-worn is very dangerous, the
over-worn tires are unsuitable for ground adhesion and driving.

The proper tire pressure will ensure the maximum stability, comfortable driving and durability
of tire. Please check the tire pressure regularly and adjust it as needed. Please change a new tire
when the tread depth of the central tire thread is at the level as below:

TIRE

MINIMUM THICKNESS OF TIRE TREAD

FRONT TIRE
REAR TIRE

1.6mm

2.0mm

48

The air lter oil accumulation pipe should be often checked, and discharge the oil if there is
some in the oil accumulation pipe.

Discharge approach:
loosen the clamp and move upward take out the drain plug from the pipe, and discharge all
the oil stored in the pipe, and then plug in the drain end, and nally loosen the clamp, move
downward and clamp the drain end tightly.

OIL ACCUMULATION PIPE

49

The air lter should be maintained regularly, and more frequent service should be given if
driven under dusty or sandy areas.

1. Take down the air lter installed on the right front of the motorcycle.

2. Remove the air lter side cover and take out the lter cartridge of air lter.

3. Wash the air lter cartridge in the clean washing oil and make it fully dry.

4. Fully immerse the lter cartridge into the clean gear oil, and then squeeze out the excess
oil.

5. Install every part in the reverse order of dismantling.

SERVICING OF AIR FILTER

50

In order to meet the requirements of environmental emission, the muer of the motorcycle is
equipped with catalytic converter.
The catalytic converter contains precious metals as the catalyst, which will transform the
hazardous substances in the tail gas of motorcycle, including carbon monoxide, hydrocarbon
and nitrogen oxide etc into non-toxic carbon dioxide, water and nitrogen through chemical
reaction.
Since the catalytic converter is very important, the defective catalytic converter will pollute the
air and damage the performance of the engine, if the replacement is needed, please use the
genuine parts.

CATALYTIC CONVERTER

The catalytic converter is at high temperature area, please do not touch.

51

The motorcycle is equipped with a fuel evaporation control device: canister. The canister is
installed under the storage battery cell, the inside of the canister is lled with vapor-absorbing
active carbon particles which can eectively prevent the residue fuel vapor evaporating into
the air, and be fuel-saving and environment friendly at the same time.

There is a port on the fuel pump, and the fuel goes through the fuel lter and reaches fuel
injector and nally the fuel will be injected into the inlet air pipe.
The connection method of fuel inlet and fuel return pipe is shown in the graph as below. The
port in the upper end of fuel pump is connected to the port in the top of fuel tank.

CANISTER

FUEL INJECTOR AND OIL PASSAGE

FUEL INJECTOR

FUEL FILTER

FUEL PUMP

52

Appropriate lubrication is quite important to ensure the normal operation of every part in
the motorcycle, extend the service life of motorcycle and guarantee the safe driving. We
suggest that the lubrication maintenance should be made after long-time riding or cleaning or
exposure in the rain. The key points of lubrication maintenance are seen as bellows:

Lubricating oil for motorcycle : Y , Lubricating Grease: Z

1) rear brake pedal shaft: Z

2) speedometer exible: Y

3) Speedometer gear and gear shaft bearing: Z,*

4) Kick stand support joint and spring hook: Z

5) Gear-shifting pedal lever pin shaft: Z

6) Accelerator: Y

7) Front brake handle pin shaft: Z

8) Clutch handle (pin shaft): Y

LUBRICATION OF PARTS

The lubricating items marked with“ * ” should be operated by the professional technicians from the
authorised dealers.

53

When the storage battery is used for the rst time, please operate based on the steps below:

Remove the vent gum cap, ll the storage battery electrolyte into the position between upper
limit (UPPER) and lower limit (LOWER), stand for 30 minutes and use after the chemical reaction
is complete. Please check if the electrolyte level is between the upper limit and lower limit
before using. Make sure to use electrolyte provided.

When the new storage battery is used for the rst time, it should be initially charged after
lling electrolyte. This should be operated by the distributors.

Please connect the wire poles correctly, positive lead (red wire) must be connected to the
positive terminal( + ) while negative lead (black wire) to negative terminal( - ), and tighten the
terminal bolt. Please use the wire brush to clear away the corrosive substances on the terminal
frequently.

The storage battery should be installed steadily and the vent line should be installed properly
to ensure the vent line is connected to the vent of storage battery.

STORAGE BAT TERY

54

Please pay attention to the following details

Please check the electrolyte level of storage battery frequently and keep it next to the (UPPER)
mark, which is the perfect position.
Power shortage of storage battery will cause dicult starting, dim lights and harsh sound of
horn, under these circumstances, please check the storage battery timely and add electrolyte
or charge accordingly.
Frequent starting, short distance driving, long time low-speed driving, frequent braking or
installing extra electrical parts will speed up the discharge of storage battery, and increase the
load of storage battery, which will cause power shortage and shorten the service life, so please
check storage battery frequently and add electrolyte or charge accordingly.

Driving the motorcycle in the case of insucient storage battery electroly te will lead to sulfurization and
damage the storage battery plate.
Please make sure that the vent pipe is connected to the storage bat tery vent when checking the storage
battery plate and lling distilled water. Please do not squeeze, bend or twist the vent pipe, or place the vent
pipe port against the parts so as not to erode the parts.
Only used distilled water to ll the batter y, using tap water will shorten the service life of storage battery.
Make sure the liquid level is between the upper limit (UPPER) and lower limit (LOWER).
Please do not knock or upside down the storage battery during dismantling and maintenance.
When installing the storage bat tery, make sure to correctly connect the lead wire. If the lead wire is inversely
connected, the circuitry and battery will be damaged. Red wire must be connected to the positive terminal
(+) while black wire to negative terminal(-).
Power switch (key) must be o during check or battery replacement.

55

Battery electrolyte:

The storage battery is located inside the storage battery cell below the cushion. The electrolyte
level should be kept between the upper level mark(UPPER LEVEL) and lower level mark(LOWER
LEVER) on the side of storage battery. If the electrolyte level is lower than the lower level
mark(LOWER LEVER), please take down the uid feeding cap cover and use a small plastic
funnel to add the distilled water into the upper level mark (UPPER LEVEL).

Please make sure that the vent pipe is connected to the storage bat tery vent when checking the storage
battery plate and lling distilled water. Please do not bend or twist the vent pipe. Make sure the vent pipe
port is facing the ground, not facing the parts, otherwise the storage battery electrolyte may erode the
swinging arm and chains.
Only the distilled water can be used, using tap water will shorten the service life of storage batter y.

56

The storage battery will bring about explosive gas, so be cautious of spark and ame.
The storage battery contains vitriol (electroly te), and any contact with it in eye or skin might lead to severe
burn. The electrolyte is toxic so keep it away from children.

Take down the storage battery to check or to add electrolyte based on the steps as below:

a. Turn o the motorcycle power switch
b. Remove the cushion rst;
c. Remove the install screw
d. Remove the negative terminal ( - ) and remove the positive terminal ( + )
e. Take out the storage battery gently , Install the storage battery in the reverse order of
dismantling

57

Don’t use the fuse out of the designated specication, or it will bring serious negative eects to the electric
system.

Replacement of the Fuse

Fuse compartment is located near the storage battery. There should be short-circuit or circuit
overload if the blowout of fuse happens frequently, Please entrust the Sales Distributor to
repair as soon as possible.

Replacement of bulbs

When replacing the bulbs, the bulbs of the same rated power and specication must be used. If
a bulb of dierent rated power is used, the circuitry may be overloaded and the bulb damaged.

58

Storage:

If the vehicle is to be kept for a long time, certain maintenance measures should be taken to
reduce the eect of long-time storage on the quality of the motorcycle.

1. Replace the engine oil.

2. Lubricate the drive chain.

3. To empty the fuel in the fuel tank and the fuel injection unit.

4. Remove the spark plug and inject one spoon (15-20cm3) of clean engine oil into the
cylinder, then install the spark plug again.

The gasoline will deteriorate if stored in the fuel tank for a long time; the deteriorated fuel will cause dicult
starting.

The gasoline is extremely inammable and may explode under cer tain conditions. Please do not smoke or
make spark nearby when draining gasoline.

STORAGE GUIDANCE

59

5. Remove the storage battery, and keep it in the place free from freezing and direct sunlight

6. Clean and dry the motorcycle. Wax all the painting surfaces.

7. Inate the tire into recommended tire pressure. Place the motorcycle above cushion block,

making the two tires o the ground.

8. Cover the motorcycle (do not use plastic or coating materials) and store it in the place with

no heat and moisture and having the minimum temperature variation. Please do not keep the
motorcycle in the environment of direct sunlight.

Use after storage

Take o the covered materials and clean the motorcycle. If the motorcycle is stored for more
than 4 months, please replace the engine oil.
Check the storage battery electrolyte level, and charge and install properly as required.
Please carry out the complete pre-driving check. Do the test driving at low speed in the safe
area.

When the engine runs, the ignition switch should be placed at o position.

60

SPECIFICATIONS AND TECHNICAL PARAMETERS

Length Front Shock Absorber

Storage battery

Fuel tank (including reser ve)

Maximu m design speed

Standard fuel consumption

Turn signal lamp

2120mm Sleeve, Oil Damping Type

12V

15L

15L

15L

12V LED

Curb Weight 220kg

Height Fro nt Braking Type

Head lamp

Engine oil

Braking distance

Rated maximum loading
capacity

Low beam in itial vertical
inclined height

Fue l Type

ECU control unit

1100mm Manually-Operated Braking

12V 35/35W

1.8 L

1.8 L

150 kg

54 0-720 mm

above 90 nu mber fuel

12V

Style

BJ465MS-A four cylinder,

four stroke, water-cooling

Width Rear Shock Absorber

Magneto

Reserve

Climbing ability

Carrying capacity

Fuel injection uni t

800mm Hydraulic Spring Type

y-wheel permanent-magnet

1.4L

1.4L

1.4L

12V

Engine

Size Frame

Electric System

Capacity

Key Properties

Wheel Base Rear Braking Type

Rear lamp/brake lamp

1480mm Pedal Braking

12V LED Cylinder Bore x Stroke

Sparking Mode

Primary Reduction Ratio

Maximum Power

Clutch

Starting Mode

First Gear Transmission Ratio

Third Gear Transmission Ratio

Fifth Gear Transmission Ratio

65.0×45.2mm

CDI

1.864

60.0KW/11000r/min

wet multiple-disc

Electric Starting

2.846

1.556

1.190

Displacement

Compression Ratio

Final Reduction Ratio

Maximum Torque

Tranmission Mode

Transmission System

Second Gear Transmission Ratio

Fourth Gear Transmission Ratio

Sixth Gear Transmission Ratio

600ml

11.5

3.286

55.0N.m/8000r/min

six-speed, constant mesh

1.947

1.333

1.083

61

NOTES:

62

NOTES: