Universal: any platform, first week
| Symptom | Likely cause | Fix |
|---|---|---|
| Will not start after unloading | Battery discharged in transit; fuel tank empty or stale; kill switch off; sidestand/clutch interlock. | Charge the battery fully (not a quick boost). Fresh fuel, prime the pump 3–4 key cycles. Kill switch to RUN, neutral, sidestand up. Then crank in 5-second bursts. |
| Starts, dies when the throttle opens | Injector rail empty / fuel pump plug off; on carb bikes a blocked pilot jet. | EFI: check the pump connector under the tank, listen for the 2-second whine at key-on. Carb: drain the bowl, clean the pilot jet. |
| Warning lamp on the dash | A connector loosened in transit, or a system that needs a relearn (ABS, TPS, IMU). | Reseat every connector under the tank and seat first. ABS clears after riding > 10 km/h. Read the code before replacing anything. |
| Battery flat again next morning | Parasitic drain from a tracker/alarm, or a charging fault. | Measure draw with the key off (< 10 mA normal). Check 13.8–14.5 V across the battery at 5,000 rpm. |
| Something rattles / a bolt is missing | Crating removes parts; hardware bag not fully used. | Go through the torque list on the assembly page; count the hardware bag against the diagram. |
NC450-class 450cc single (enduro, rally, ADV)
| Symptom | Likely cause | Fix |
|---|---|---|
| Will not start after unloading; starter clicks or is slow | Battery discharged during 4–8 weeks of shipping (often shipped disconnected, sometimes partially charged). | Charge with a smart charger at 1–2 A for 6–10 hours before first start. Do not jump-start from a car with the engine running. If the battery will not hold 12.5 V after charging, replace it (claimable within the first 30 days). |
| Starts, then stalls; rough idle; smells of stale fuel | Factory test fuel has aged during transport, or the tank was drained and the injector rail is empty. | Fill with fresh 92–95 RON, cycle the key 3–4 times to prime the pump (listen for the 2-second whine), then crank. Idle for 5 minutes with the throttle closed so the ECU relearns. |
| Fault lamp on; ECU error code | A sensor connector loosened in transit (TPS, oxygen sensor, coolant temperature) or a disconnected fuel-pump plug. | Read the code: most Delphi-type ECUs blink the MIL when the diagnostic pin is bridged, or use a generic OBD-M / K-line reader (provided on request). Reseat every connector under the tank first; 80% of codes clear after this. |
| Engine overheats in slow riding; fan not running | Air lock in the cooling system, fan fuse pulled for shipping, or fan thermo-switch connector off. | Bleed the system: loosen the bleed screw or top hose with the engine warm, top up. Check the fan fuse (usually 10–15 A) and that the fan runs when 12 V is applied directly. Normal fan-on temperature is ≈ 95–100 °C. |
| Chain slaps or jumps; noise from the rear | Chain set loose for crating or over-tight at assembly. | Set slack to ≈ 35–45 mm at the tightest point with the bike on its stand; align using the swingarm marks; torque the axle. |
| Charging voltage low; battery drains overnight | Regulator/rectifier connector corroded, or a parasitic drain from an aftermarket alarm/GPS fitted at the factory. | Measure 13.8–14.5 V at 5,000 rpm across the battery. If lower, check the stator AC output (typically 20–70 V AC per phase, rising with rpm) and the regulator plug. Disconnect any tracker fitted and measure current draw (<10 mA is normal). |
| Oil weeping from the head cover or clutch cover after the first 500 km | Gaskets settle during break-in; bolts loosen slightly. | Re-torque the cover bolts in a cross pattern to ≈ 10–12 Nm. Persistent leaks: replace the gasket (in the spare-parts kit). |
| Hard gear engagement / false neutrals | Clutch cable stretch after break-in, or wrong oil (car oil with friction modifiers). | Set 10–15 mm free play at the lever; use JASO MA2 motorcycle oil only. |
500cc parallel-twin (street, naked, mini-ADV)
| Symptom | Likely cause | Fix |
|---|---|---|
| ABS warning stays on after assembly | Wheel-speed sensor gap wrong after refitting the front wheel, or sensor plug off. | Set the sensor-to-ring gap to ≈ 0.5–1.5 mm, reconnect, ride above 10 km/h — the lamp self-clears. |
| Uneven idle, one header cooler than the other | Throttle bodies out of sync or an injector plug loose. | Check both injector connectors; sync with a vacuum gauge set at idle per manual. |
| Will not start after shipping | Flat battery / stale fuel. | Charge battery, fresh fuel, prime pump 3× with the key, crank. |
| Fan runs constantly / temperature gauge high | Air in the cooling system after the factory drained it for crating (rare) or a bent radiator. | Bleed and top up; check the radiator for transit damage and claim with photos if bent. |
| Clutch drag when cold | Oil viscosity / cable free play. | 10W-40 JASO MA2, 10–15 mm lever play; slipper-clutch units settle after 1,000 km. |
250cc single (enduro / trail)
| Symptom | Likely cause | Fix |
|---|---|---|
| Carburettor model floods / idles badly after shipping | Stale fuel varnish in the pilot jet; float stuck. | Drain the bowl, clean the pilot jet with carb cleaner and compressed air, fresh fuel. |
| Kick start only, no electric start | Flat battery or starter relay connector. | Charge; check the relay plug behind the side cover. |
| Ticking from the head increasing with rpm | Valve clearance opened up during break-in. | Adjust at 500 km — takes 20 minutes with screw adjusters. |
| Oil in the airbox | Overfilled crankcase (common at factory). | Set the level to the dipstick/sight-glass mid-mark, not the top. |
250–300cc street single / twin (value big bikes)
| Symptom | Likely cause | Fix |
|---|---|---|
| TFT / LCD dash blank | Dash connector unplugged for crating; main fuse pulled. | Check the fuse box under the seat and the dash multiplug behind the headlight. |
| Altitude (Andes) — rich running, black smoke | Basic ECU maps without barometric correction on some cheap variants. | Specify the EFI version with a MAP/baro sensor when ordering for markets above 2,000 m — we flag this at quote stage. |
| Won’t start after shipping | Battery / stale fuel. | Charge, fresh fuel, prime. |
| Rattle from fairing at speed | Fasteners loosened; plastic clips missing after crating. | Re-check every fairing clip; extra clips are in the parts kit. |
400cc adventure single
| Symptom | Likely cause | Fix |
|---|---|---|
| Won’t start after shipping | Battery / stale fuel / fuel pump plug. | Charge, fresh fuel, check the pump connector under the tank. |
| Pannier racks loose | Crated with racks off; bolts hand-tight. | Torque rack bolts to ≈ 25 Nm with thread-lock. |
| Windscreen cracks at bolt holes | Over-tightened during assembly. | Use the rubber washers supplied; hand-tight + ¼ turn. |
650cc parallel-twin adventure tourer
| Symptom | Likely cause | Fix |
|---|---|---|
| TCS / ride-mode warning after battery reconnect | Throttle grip needs relearn after power loss. | Key on, do not touch the throttle for 10 s, then twist fully open/closed twice; ride to clear. |
| ABS lamp on | Wheel sensor gap after wheel refit. | Set 0.5–1.5 mm, ride above 10 km/h. |
| Won’t start after shipping | Battery / fuel. | Charge; fresh fuel; prime. |
650cc V-twin cruiser
| Symptom | Likely cause | Fix |
|---|---|---|
| Belt squeal | Belt too tight after assembly or debris on the pulley. | Set deflection per manual; clean pulleys. |
| Won’t start after shipping | Battery / fuel. | Charge; fresh fuel; prime. |
| Chrome pitting in coastal / Gulf climates | Salt air. | Wax chrome on PDI; keep showroom units covered. |
CG / CB-type 150–200cc commuter & cargo
| Symptom | Likely cause | Fix |
|---|---|---|
| Won’t start; kick only | Flat battery — small 12 V 5–7 Ah batteries lose charge fast in transit. | Charge 4–6 h at 0.5–1 A; if below 12.4 V rested after charge, replace. |
| Hunting idle / stalls warm (carb) | Pilot jet varnish; idle mixture screw disturbed. | Clean jets; set the mixture screw 1½–2½ turns out, idle 1,400 ± 100 rpm. |
| Oil consumption after 5,000 km in taxi use | Air filter neglected; dust wears rings. | Enforce filter cleaning; sell filters with every service. |
| Rear brake drum squeal | Dust / glazed shoes. | Clean drum, light sand of shoes. |
| Headlight dim at idle | AC lighting circuit on cheapest variants. | Normal for AC-lighting bikes; DC-lighting or LED versions are available at order time. |
Electric motorcycle & scooter (2–5 kW class)
| Symptom | Likely cause | Fix |
|---|---|---|
| Dead on arrival — no dash, no power | Battery shipped at 30–50% and disconnected; main breaker / fuse off; key-switch plug off. Lithium packs with a BMS may “sleep” below a voltage threshold. | Reconnect the pack, switch on the breaker, charge to 100%. If the BMS is in sleep, most wake when the charger is connected for 30–60 s; some need the charger connected before the discharge plug. |
| Charger LED stays red / green immediately, no charging | Charger polarity plug mismatch, wrong voltage charger, or BMS over-temperature lockout. | Match charger voltage to pack (60 vs 72 V). Let the pack cool below 45 °C. If the charger shows green at once, the BMS is refusing — check the pack’s balance leads or claim. |
| Motor cuts out under load; dash shows error code | Controller over-current / hall sensor fault / phase wire loose after transit. | Common controller codes: E1/E2 throttle, E3 controller, E4 motor hall, E5 brake switch, E6 under-voltage, E7 over-current, E8 motor phase (vendor-specific — the sheet in the parts kit lists yours). Reseat the three thick phase connectors and the five-pin hall plug; look for melted pins. |
| No throttle response, dash on | Brake-lever switch stuck on (kill signal), sidestand switch, or throttle plug. | Check both brake-lever switches with a meter; the controller will not drive while a brake switch is closed. |
| Range 30% below spec | Low tire pressure, cold weather, lead-acid pack sulphated during shipping, or rider in Sport mode. | Pressures first; three full cycles to recover lead-acid; check mode. Lithium packs stored > 3 months below 20% may have lost capacity — claim with a capacity test. |
| Intermittent power, dash resets | Loose main negative or corroded Anderson connector. | Clean, tighten, dielectric grease. |
| Regen / reverse not working | Feature disabled in controller parameters for the export market. | Set via the controller app/programmer; we supply the parameter sheet. |
1000cc 4×4 UTV / side-by-side
| Symptom | Likely cause | Fix |
|---|---|---|
| Will not start; dash lights but no crank | Battery low, brake pedal not pressed (interlock), gear not in P/N, seat-belt interlock on some models. | Charge battery; press brake; confirm P/N; check seat-belt switch plug under the seat. |
| CVT belt slips / burning smell | Belt not bedded, water in the CVT case, or oil contamination from a leaking seal. | Bed the belt (50 km gentle); drain CVT housing via the drain plug at the bottom; clean pulleys with brake cleaner; replace belt if glazed. |
| Overheats at low speed | Radiator mud-packed, fan fuse/relay, air lock. | Pressure-wash the radiator from the engine side; check the 30 A fan fuse; bleed. |
| 4WD will not engage / diff-lock light flashes | Actuator plug off, vacuum/electric actuator stuck, or engaging while rolling. | Engage 4WD at standstill or rolling straight below 5 km/h; check the actuator connector on the front diff; cycle the switch 3× with the key on. |
| Clunk on take-off | Driveshaft splines dry or U-joint play. | Grease splines; check U-joints — claimable if loose on PDI. |
| Steering pulls / wanders | Toe out of spec after shipping tie-downs; tie-rod ends loose. | Set toe to ≈ 0–3 mm toe-in; torque tie-rod nuts; check EPS connector if fitted. |
| Fault code on EFI | Connector loosened in transit. | Read via diagnostic port (kit available); reseat connectors under the hood and seat. |
300cc utility ATV
| Symptom | Likely cause | Fix |
|---|---|---|
| Won’t start | Battery, brake-lever interlock, kill switch left off. | Charge; hold the brake; kill switch to RUN. |
| Belt slips in water crossings | Water in CVT housing. | Open the CVT drain plug; dry; check vent hose routing above the seat line. |
| Reverse hard to engage | Cable adjustment; shifter linkage loose after crating. | Adjust the shift cable; torque linkage. |
| Pulls to one side | Tire pressures uneven (very sensitive at 5 psi) or toe out. | Equalise pressures with a low-range gauge; set toe. |
ZXMOTO inline-three (820RR) & inline-four (500RR / 500F)
| Symptom | Likely cause | Fix |
|---|---|---|
| Riding-mode / IMU warning after battery reconnect | IMU and TPS need a relearn. | Key on, bike upright and still for 10 s, then throttle relearn; ride to clear. Persisting codes: dealer tool. |
| Quickshifter not cutting | Shift-rod sensor plug off or feature off in the menu. | Reconnect; enable in the TFT menu. |
| Will not start after shipping | Battery / stale fuel / immobiliser key not paired (some units ship with one key active). | Charge; fresh fuel; use the key marked as primary; pair the second key per the manual. |
| ABS lamp | Wheel-sensor gap after wheel refit. | Set gap; ride above 10 km/h. |
Not solved in 30 minutes? Send VIN + photo + a 30-second video of the symptom to WhatsApp +1 646 235 7816. Reply within 48 hours; manufacturing defects go straight to a claim.