CONTENTS

CHAPTER 1 GENERAL

1.1 VEHICLE INTRODUCTION-------------------------------------------------------------------------------------------------------1-1

1.2 SPECIFICATIONS-----------------------------------------------------------------------------------------------------------------------1-2

CHAPTER 2 ENGINE

2.1 CYLINDER HEAD-------------------------------------------------------------------------------------------------------------------2-1

2.2 CYLINDER BLOCK-----------------------------------------------------------------------------------------------------------------2-8

2.3 VALVE TRAIN----------------------------------------------------------------------------------------------------------------------- 2-11

2.4 TRANSMISSION --------------------------------------------------------------------------------------------------------------------2-16

2.5 CRANKCASE-------------------------------------------------------------------------------------------------------------------------2-30

2.6 CRANK MECHANISM-------------------------------------------------------------------------------------------------------------2-36

2.7 STARTERS----------------------------------------------------------------------------------------------------------------------------2-40

2.8 LUBRICATION SYSTEM----------------------------------------------------------------------------------------------------------2-48

CHAPTER 3 CHASSIS

3.1 FRAME BODY-----------------------------------------------------------------------------------------------------------------------3-1

3.2 SUSPENSION SYSTEM ----------------------------------------------------------------------------------------------------------3-6

3.3 FRONT SUSPENSION ------------------------------------------------------------------------------------------------------------3-9

3.4 REAR SUSPENSION --------------------------------------------------------------------------------------------------------------3-13

3.5 FRONT AND REAR WHEELS --------------------------------------------------------------------------------------------------3-15

3.6 INTAKE SYSTEM AND EXHAUST SYSTEM -------------------------------------------------------------------------------3-21

3.7 COOLING SYSTEM----------------------------------------------------------------------------------------------------------------3-25

CHAPTER 4 ELECTRICAL COMPONENTS AND METER

4.1 CHARGING SYSTEM-------------------------------------------------------------------------------------------------------------4-4

4.2 EFI SYSTEM ------------------------------------------------------------------------------------------------------------------------4-7

4.3 IGNITION SYSTEM ---------------------------------------------------------------------------------------------------------------4-19

4.4 SIGNAL SYSTEM, METER, RADIATOR FAN AND WATER TEMPERATURE INDICATOR----------------------4-22
4.5 LIGHTING SYSTEM------------------------------------------------------------------------------------------------------------ 4-29

4.6 ELECTRIC STARTING SYSTEM ---------------------------------------------------------------------------------------------4-32

4.7 BATTERY AND FUSE -----------------------------------------------------------------------------------------------------------4-34

4.8 ELECTRICAL HORN ------------------------------------------------------------------------------------------------------------4-36

CHAPTER 5 SERVICE

5.1 ROUTINE MAINTENANCE AND ADJUSTMENT -----------------------------------------------------------------------5-1

5.2 PRE-RIDE INSPECTION -------------------------------------------------------------------------------------------------------5-4

5.3 GENERAL MAINTENANCE

5.3.1 Tool Kit ---------------------------------------------------------------------------------------------------------------5-4

5.3.2 Maintenance Schedule ----------------------------------------------------------------------------------------------5-5

5.4 STORAGE ------------------------------------------------------------------------------------------------------------------------5-6

5.5 UNPACKING---------------------------------------------------------------------------------------------------------------------5-6
 FOREWORD

This manual covers the structure, operation, inspection, maintenance and repair of LF200-10P motorcycle for use by the LIFAN dealers and
qualified mechanics. With both the descriptions and figures/drawings, you may have a comprehensive understanding of the structure as well as
service and repair skill.
Lifan Industry (group) Co., Ltd. is continually striving to improve all its models. All information in this publication is based on the latest
product information available at the time of printing. LIFAN reserves the right of make changes at any time without notice and without incurring
any obligation.
No part of this publication may be reproduced without written permission.

LIFAN INDUSTRY (GROUP) CO., LTD.

March, 2016
 CHAPTER 1 GENERAL
1.1 VEHICLE INTRODUCTION
The LF200-10P motorcycle is one of the lately developed products with comfortable riding, easily operation and safe transportation. Installed on the
vehicle is 165MJ-P engine which is of vertical single cylinder, 4-stroke and air cooled type. The vehicle
⑨ ⑧ ⑥ ⑦ ④ ⑨ ⑦ ⑥ ⑤ ④

① ② ③ ⑩ ⑤ ⑧ ② ① ③
①Exhaust muffler ② Main step ③Radiator ④Front Wheel ①Gearshift pedal ②Side stand ③Rear wheel ④Taillight
⑤Front shock absorber ⑥Front winker ⑦Headlight ⑤Rear handrail ⑥Fuel Tank ⑦Meter ⑧Front fender
⑧Rear shock absorber ⑨Seat ⑩Front brake ⑨Rear mirror

1-1
1.2 SPECIFICATIONS
ITEM SPECIFICATIONS
Length ×Width × Height 2060mm×760mm×1105mm
Wheelbase 1330mm
Dimension and Weight Ground clearance 160mm
Kerb mass 138kg
Max. weight capacity 150kg
Model 165ML-P
Type Single-cylinder, 4-stroke and water-colled
Bore × stroke 65.5mm×58.8mm
Displacement 198 ml
Compression ratio 11：1
Carburetor type / (EFI)
Engine
Air cleaner Plastic housing with paper and foam element
Lubrication Press/splash
Starting mode Electric
Max. net power 12.5kW/8000r/min
Max. torque 17N·m /6500r/min
Idle speed 1500 r/min
Front shock absorber Telescopic type hydraulic drive
Rear shock absorber Spring type hydraulic drive
Riding system Steering bar angle ≤36°
Tyre Front 90/90-17-4PR/175kPa
size/pressure Rear 120/80-17-4PR/200kPa
Riding system Drive mode Chain

1-2
 Turning circle dia. 4860mm
Clutch Wet, multi-plate type
Transmission 6-speed, constant mesh
Primary reduction 3.333
Final reduction 2.800
1st 2.909
Drive Train 2nd 1.867
Gear ratio 3rd 1.316
4th 1.000
5th 0.833
Type 08MC
Drive chain
Link No. 126
Front Disk
Brake
Rear Disk
Ignition Inductive energy storage
Static ignition timing (°CA) 40°
Spark plug CPR8EA
Spark plug gap 0.9±0.05mm
Battery 12N9-BS
Electrical Fuse 20A
Headlight LED20W/10W
Front position light LED/2.7W
Tail/stop light LED0.3 W /1.7W
Winker 12V10W
Oil level warning light LED/8mA

1-3
 High beam indicator LED/8mA
urn signal indicator LED/8mA
Meter light LED/8mA
Fuel type RQ-93
Capacity 14L
Fuel tank
Reserve 2.8L
Fuel/Oil Brand 15W/40-SF
Engine oil
Capacity 1L
Brand HQ-10
Damping oil
Capacity 320ml

1-4
 CHAPTER 2 ENGINE

2.1 CYLINDER HEAD

2.1.1 Removal, Maintenance and Installation
1）Remove the bolt of oil passage and kick the starter rod to run the engine. 3）Adjust the valve gap.
Check to see if oil flows from the view-hole. Clean the oil passage/line, if
necessary.
(NOTE: Bolt specification: M6×12 Tightening torque of bolt 8～12N·m）

2）Unscrew the fixing bolt of valve cover and remove the valve cover. 4）Unscrew and remove the fixing bolt M8 of cylinder head.
(NOTE: Bolt specification: M6×12 Tightening torque of bolt 8～12N·m） (Tightening torque30～40N.m)

2-1
5）Unscrew and remove the connecting bolt of cylinder head left cover and 7）Unscrew and remove the fixing bolt M6×10 of the timing driven sprocket.
remove the valve cover. Remove the timing driven sprocket and camshaft assembly.
(NOTE: Bolt specification: M6×14 Tightening torque of bolt 8～12N·m） (Tightening torque of bolt 8～12N·m）

6）Check the cylinder head left cover, valve cover and the gasket for damage. 8）Check the timing drive sprocket and camshaft assembly for wear, damage or
Replace it if necessary. deformation. Replace them if necessary.

2-2
9）Structure of cylinder head assembly is as follows: 11）Remove the cylinder head assembly.

10）Unscrew and remove the connecting bolt of cylinder head. 12）Remove the split cone, valve spring and valve. Check them for wear.
(NOTE: Hexagon socket bolt specification: M6×14 Tightening torque of Replace the worn parts if necessary.
bolt 8～12N·m）

2-3
13）Measure the width of effective sealing face. Replace the cylinder head or 15）Measure I.D. of valve guide. If it is out of the limit, replace the worn valve
valve if it is beyond the limit. Service limit:＞1.6mm guide. Service limit: ＞Φ 5.54mm

14）Ream the valve seat to specified value. Replace it if it is beyond the limit. 16）Unscrew the spark plug M10×1. Clear away carbon deposit around the
Standard valve: intakeΦ 29±0.05mm，exhaustΦ 25±0.05mm spark plug. The spark plug gap should be controlled between the scope of
0.8～0.9mm.
(NOTE: Tightening torque of spark plug M10×1:10～20N.m)

2-4
17) Unscrew and remove the bolt of thermostat and remove the thermostat.
(NOTE: Bolt specification: M6×16 Tightening torque of bolt 8～12N.m）

2-5
2.1.2 Troubleshooting to Cylinder Head

Trouble Symptom of
Description Damage Form Trouble Symptom of Motorcycle Remedy
Component
Carbon deposit in the
Engine overheats Clear away the carbon deposit.
combustion chamber
Air leakage between
Threaded hole of spark
spark plug and Engine fails or is hard to start Repair threaded hole or replace the cylinder head
plug is damaged
cylinder head
Seriously deformation
Air leakage between Engine fails or is hard to start. Engine
Cylinder of cylinder head surface Grind the cylinder head surface or replace the
cylinder head and lacks power.
Head (i.e. the deformation is out cylinder head
cylinder Unstable idle speed
of 0.05mm）
Defects such as pits, Air leakage between
erosion, etc. are found on valve and valve seat
Do. Grind the valve seat and valve
the contact area of valve due to improper
seat. tightness

I.D. of valve guide is Eccentric wear of valve seat cause air

Valve stem-to-guide
out of specification (i.e. leakage of valve, hard starting of Replace valve guide or cylinder head
clearance is too large
its I.D. is out of 5.54mm） engine, and unstable idle speed

Air leakage between Engine fails or is hard to start. Engine

Locknut of cylinder head
cylinder head and lacks power. Screw up the locknut
is not properly tightened
cylinder Unstable idle speed

2-6
 Improper gap between
Engine fails or is hard to start. Engine Adjust by slightly bend the side electrode till the gap
electrodes Weak or no spark
lacks power. Unstable idle speed is 0.8-0.9 mm

Electrodes are jointed by

Weak or no spark Engine fails to start. Remove carbon deposit from electrodes
carbon deposit
Too much carbon deposit
Spark Engine fails or is hard to start. Engine
or over-oiled dirt around Weak or no spark Clear away carbon deposit or oiled dirt
plug lacks power. Unstable idle speed
the spark plug
Engine fails or is hard to start. Engine Replace the damaged spark plug with a new one of
Spark plug is damaged Weak or no spark
lacks power. Unstable idle speed the same type
Air leakage between
Engine is hard to start. Unstable idle
Loose park plug spark and cylinder Tighten up spark plug
speed
head
Air intake and exhaust Engine lacks power. Too much noise
Excessive wear for cam Replace the cam
is not smooth from valve train.
Camshaft Excessive wear for timing Too much clearance Abnormal sound from camshaft
Replace the timing driven sprocket
assembly driven sprocket hole between hole and shaft assembly
Excessive wear for Too much clearance Abnormal sound from camshaft
Replace the camshaft and shaft sleeve
camshaft between hole and shaft assembly
Thermostat is damaged or
Thermostat Poor rejection of heat Engine overheats Replace the thermostat or tighten up the plug
plug is loose

2-7
 2.2 CYLINDER BLOCK
2.2.1 Removal, Maintenance and Installation
1）Remove the cylinder head gasket and dowel pins. Check them for damage. 3）Remove the cylinder block.
Replace them if necessary.

Gasket

Dowel pin

4）Remove the gasket (thickness: 0.5mm) of cylinder block. Check it for wear.
Replace it if necessary.

2）Unscrew and remove the fixing bolt of water pipe. Remove the water pipe
and check the pipe for crack. Replace it if necessary.

2-8
5）Remove the circlip of piston pin.（Caution: do not make the circlip falls into 7) Check and measure the cylinder wall. If it is out of the service limit, replace
the crankcase） the cylinder. Service limit: ＞Φ 65.55mm

CIRCLIP

6）Pull out the piston pin and check it for wear. Replace it if it is out of the
service limit. Service limit: ＜Φ 14.95mm

8) Check the water passage for blocking.

Water inlet

2-9
2.2.2 Troubleshooting to Cylinder Block

Trouble Symptom of Trouble Symptom of

Description Damage Form Remedy
Component Motorcycle
Engine fails or is hard to
Seriously deformation of Air leakage between the Grind the cylinder head jointing surface
start. Engine lacks power.
cylinder joining surface cylinder head and block or replace the cylinder head
Unstable idle speed
Engine fails or is hard to
Cylinder block-to-piston/ start. Engine lacks power.
Cylinder Block The cylinder block is worn
piston ring clearance is too Unstable idle speed. Thick Replace the cylinder
considerably
large blue and white smoke from
the exhaust pipe
Oil leakage between the
Cylinder gasket is damaged Replace the cylinder gasket
cylinder block and crankcase

2-10
 2.3 VALVE TRAIN
2.3.1 Removal, Maintenance and Installation 3）Remove the valve spring, and check it for wear or deformation. Repair or
1）Check the intake/exhaust valve for air tightness. Grind the valve if necessary。 replace it if necessary.

4）Remove the valve stem seal, and check it for wear or damage. Replace it if
2）Remove the split cones, valve spring seat. Check them for wear. necessary.
Repair or replace them according to the actual situation.

2-11
5）Remove the intake/exhaust valve. Check them for serious wear. Replace them Measure the diameter of valve stem. If it is beyond the service limit, replace the
if necessary. valve. Service limit: ＜Φ 4.95mm

INTAKE VALVE EXHAUST VALVE

6）Measure the margin and face of valve. If any one of the values is beyond the 7）Measure the free length of the spring. If it is beyond the service limit (outer:
service limit, replace the valve. ＜36mm inner: ＜34 mm）, replace the spring with a new one.
Face angle: 45° Margin: 1.6mm NOTE: The loose wound coils face upward when installing the springs.

2-12
8）Unscrew and remove the fixing bolt M6×12 of valve rocker fixing plate and 10）Unscrew the bolt M6 of left crankcase cover and remove the left crankcase
remove the rocker. cover. Tightening torque: 8～12N.m
Tightening torque of bolt: 8～12N.m

9）The construction of rocker holder is shown in following figure. Check the

rocker holder for excessive wear or inflexible rotation. Replace it if necessary. 11）Unscrew the bolt of magneto rotor. Remove the magneto rotor and gear with
Then remove the camshaft assembly. Check it for wear and replace it if specified equipment.
necessary.。 Bolt specification: M10×35 Tightening torque: 40～50N.m

2-13
12) Unscrew the bolt of valve cover and remove the valve cover. 14）Adjust the intake/exhaust valve to 0.05±0.02mm, then tighten up the
adjusting nut of valve.

13）Unscrew the plug on the left engine cover and plug of view hole. Rotate the
rotor of magneto until “T” mark on the rotor aligns with the index mark on the 15) Unscrew and remove the bolt M6×12 of timing chain tensioning plate.
left crankcase cover. In this case, both the intake and exhaust valves are closed. Tightening torque: 8～12N.m

PLUG OF VIEW HOLE

PLUG

2-14
 16）Check the timing chain tensioning guard plate (chain tensioning plate, chain 17）Check the timing driven sprocket and chain for wear. Replace them if
guide plate) for wear. Replace it if the wearing depth is beyond 0.5mm. necessary.

2.3.2 Troubleshooting to Valve Train

Description Damage Form Trouble Symptom of Component Trouble Symptom of Motorcycle Remedy
Rockshaft and Excessive clearance between
Knock sound Replace the rockshaft and valve rocker
valve rocker rockshaft and valve rocker
The valve is impossible to close Engine fails or is hard to start. Engine Adjust the valve clearance to 0.03～
Little valve clearance
completely lacks power. Unstable idle speed 0.05mm
Excessive valve clearance Knock sound Do.
Engine fails or is hard to start. Engine Clear away carbon deposit, grind the
Carbon deposit on the surface Valve-to-valve seat fit is not tight
lacks power. Unstable idle speed valve seat
Valve
Contact area is seriously worn
Do. Do. Do.
or has defects such as pits, etc.
Valve stem-to-guide clearance is Replace the valve
Valve stem is seriously worn Thick blue smoke from exhaust pipe
too large
The valve stem is deformed Valve is not closed completely Engine fails to start Replace the valve
Valve-to-valve seat fit is not tight Engine fails or is hard to start. Sound
Valve Spring Spring is broken Replace the valve spring
from the cylinder head
Air intake/exhaust is not smooth.
Excessive wear for the cam Engine lacks power. Too much Too much noise. Power lack when riding Replace the camshaft
Camshaft noise from valve train
Excessive wear for the Hole-to-shaft clearance is too large.
Too much noise. Replace the camshaft or shaft sleeve
camshaft Abnormal sound from cam gear
Timing chain It is too long Too long, knock sound Too much noise. Power lack when riding Replace the timing chain

2-15
 2.4 TRANSMISSION
2.4.1 Clutch
 Removal and Installation
1）Remove the gasket of right crankcase cover and check it. Replace the 3）Check the spring of clutch rod. Replace it if necessary.
damaged the gasket with a new one

4）The construction of clutch is shown as follows:

2）Check the clutch rod for wear. Replace it if necessary
CLUTCH ROD
离合器操纵杆组合

2-16
5）Extract the clutch lifter, and check it for wear. Replace it if necessary. 7）Unscrew the clutch locknut with specified equipment. Replace it if it is
deformed.
CLUTCH LIFTER

6）Remove the clutch bearing, and check it for wear. Replace it if necessary. 8）Remove the clutch driven disc comp., check it for wear. Replace it if
necessary.

2-17
 9）Remove the splined washer, and check it for wear. Replace it if necessary. 11）Remove the clutch outer comp., check the gear for wear. Replace the disc if
necessary.

10）Unscrew the bolt of primary drive gear. Remove the primary drive gear, and 12）Remove the clutch drive plate. Measure the thickness of the clutch drive
check it. Replace the worn gear with a new one. plate with the caliper. Replace the plate if the thickness is out of the limit.
Service limit: ＜2.8mm

2-18
13）Check the thickness of clutch driven plate. Replace the plate if the thickness 14）Measure the free length of clutch spring. Replace the spring if the length is
is out of the limit. out of the limit. Service limit: ＜35mm
Service limit: ＜1.4mm

2-19
2.4.2 Troubleshooting to clutch

Description Damage Form Trouble Symptom of Component Trouble Symptom of Motorcycle Remedy

Hub grooves are worn into saw Friction discs fail to remove freely Clutch slipping. Out of function. Trim the grooves with saw
Clutch outer
teeth-shaped in the hub grooves. Abnormal sound or replace the clutch outer

Clutch drive
Excessively worn Clutch slipping. Replace the plates as a set
plate

Excessively worn (i.e. the

Clutch driven Clutch slipping. Out of function.
thickness is less than 1.4mm) Replace the plates as a set
plate
Heavily deformed Clutch slipping.

Clutch spring Weak or broken Clutch slipping. Replace the spring

2.4.3 Transmission
 Removal and Installation 1） 2）Unscrew the bolt of gearshift drum stopper. Remove it.
1）Remove the gearshift shaft, and check it for wear. Replace it if necessary. (NOTE: Specification of bolt : M6×20 Tightening torque: 8～12 N•m

2-20
3）Unscrew the bolt of gearshift cam. Remove the gearshift cam 5）Unscrew fixing bolts from the crankcase, remove the right crankcase, and
(NOTE: Specification of bolt : M6×25 Tightening torque: 8～12 N•m check the gasket for damage. Replace the damaged gasket with a new one.
(Tightening torque: 8～12N.m)

RIGHT CRANKCASE

4）Check the gearshift cam for wear, and replace it if necessary. LEFT CRANKCASE
6）Remove the crank connecting rod合
comp.

CRANK CONNECTING ROD COMP.

2-21
7）Remove the gearshift fork shaft, and check it for wear. Replace it if 9）Remove the fork II, and check it for wear. Replace it if necessary.
necessary.

FORK SHAFT

8）Remove the fork I, and check it for wear. Replace it if necessary 10）Remove the fork III, and check it for wear. Replace it if necessary.

2-22
11）Remove the gearshift drum, and check it for wear. Replace it if necessary. 13）Measure the O.D. of gearshift fork shaft. If it is beyond the service limit,
replace the worn shaft with a new one.
Service limit: ＜Φ 11.90mm

12）Check the fork grooves in the gearshift drum for wear. Replace it if 14）Measure the thickness of gearshift fork and I.D. of hole in the gearshift fork
necessary. by using a micrometer and an inside micrometer separately. If any one of them
is beyond the service limit, replace the fork.
Service limit of fork thickness: 4.8mm
Service limit of fork I.D.: Ф12.5mm

2-23
15）Remove the mainshaft comp. and countershaft comp., then check them for 17）Remove the washer of starting mid-gears. Check it for wear and replace it if
proper match gap. Replace the mainshaft comp. and countershaft comp. if the the worn part is out of the limit. Service limit: 0.8mm
gap is too large.

16）Check the gears of mainshaft comp. and countershaft comp. for wear. 18）Remove the starting mid-gears on the counter shaft. Check it for wear.
Replace them if necessary (it needs to replace the gear if defects such as pits, Replace it if it is out of the limit.
teeth crack appear). Limit value of inner bore: Φ 20.1mm

2-24
19）Remove the bush and washer of starting mid-gears. Check them for wear. 21）Remove the bush of countershaft 1st gear and washer I, then check them for
Replace them if necessary. wear. Replace the worn part.

20）Remove the countershaft 1st gear, and then check it for wear. Replace the 22）Remove the countershaft 3rd gear, and then check it for wear. Replace the
worn gear if necessary. Limit value of inner bore: Φ 19.6mm worn gear if necessary.

2-25
23）Remove the washer II from the countershaft, and check it for wear. Replace 25）Remove the countershaft 5th gear, 4th gear and splined washer, then check
the washer if necessary. them for wear. Replace the worn-out part if necessary.
Limit value of inner bore: Φ 20.1mm

24）Remove the countershaft 2nd gear, and then check it for wear. Replace the 26）Remove the washer from the mainshaft, and check it for wear. Replace it if
worn gear if necessary. Limit value of inner bore: Φ 22.1mm it is out of the limit. Service limit: 0.8mm

2-26
27）Remove the 2nd gear from the mainshaft, and check it for wear. Replace the 29）Take the splined washer and circlip out of mainshaft, then check them for
washer if necessary. deformation. Replace the washer/circlip if necessary.

28）Remove the 5th gear from the mainshaft, and check it for wear. Replace the 30）Remove the 4th gear from the mainshaft, then check it for wear.
gear if necessary. Limit value of inner bore: Φ 20.1mm Replace the worn part.

2-27
31）Remove the starting driven gear set and washer, then check them for wear.
Replace the worn part.

2-28
 2.4.4 Troubleshooting to transmission

Description Damage Form Trouble Symptom of Component Trouble Symptom of Vehicle Remedy

Gear tooth surface or gear are worn-out Abnormal sound during gearbox driving. Replace the gear
or damaged Gear shifting with difficulty
Gear end face engagement claw edge is
Transmission is easy to disengage Do.
Gear worn into arc
Gear engagement hole is worn into
Shaft-to-hole clearance is too large Do. Do.
trumpet shape
Fork groove is worn-out Fork-to-groove clearance is too large Do. Do.
Claw is excessively worn Do. Do. Replace the fork
Gearshift
Fork is deformed Deformed fork Gear shifting with difficulty Do.
Fork
Fork hole is considerably worn Fork-to-drum gap is too large Do. Do.
Gearshift
Groove is worn-out Do. Replace the worn-out drum
Drum
Gearshift Excessively worn or damaged Do. Replace the stopper
Drum
Stopper Spring is weak or broken Gearshift pedal slipping Transmission is easy to disengage Replace the torque spring
Spline is damaged Gearshift lever slipping Transmission fails to engage Replace the gearshift shaft
Gearshift Gearshift shaft is deformed Gear shifting with difficulty Do.
Shaft Gearshift shaft is worn-out or broken Do. Do.
Gear shifting with difficulty. Pedal is not
Return spring is weak or broken Replace the return spring
to return
Oil Seal Oil seal is worn-out, damaged or aged Oil leakage Replace the oil seal
Bearing Excessive wear or damage Abnormal sound from the transmission Replace the bearing

2-29
 2.5 CRANKCASE
 2.5.1 Removal, Maintenance and Installation
 1）Unscrew the drain plug, empty the engine oil thoroughly. 3）Check the gasket of right crankcase cover for wear. Replace it if necessary.
(Specification of plug: M36×1.5 Tightening torque:20～30 N.m)

4）The construction of right crankcase cover comp. is shown as following figure.

2）Unscrew the bolt M6 of right crankcase cover. Remove the cover by striking Check the clutch rod for wear. Replace it if necessary.
with a rubber hammer.
Tightening torque of bolt: 8～12N.m CLUTCH ROD COMP.

2-30
5）Unscrew the bolt M6 of left crankcase cover. 7）Check the dual-gear for wear. Replace the gear if there’s pit or tooth
Tightening torque: 8～12N.m breakage.

DUAL-GEAR

6）Unscrew the fixing bolt of starter motor and idler cover. Remove the starter 8）Disconnect the magneto wire leads. Remove the left crankcase cover.
motor and idler cover. Check the O-ring for wear. Replace it if necessary.

IDLER COVER

O-RING

2-31
9）Check the gasket of left crankcase cover for damage. Replace it if necessary. 11) Unscrew and remove the bolt M6 of water inlet cover.
Tightening torque: 8～12N.m

10）Unscrew the connecting bolts from the crankcase. 12）Remove the water inlet cover.
Tightening torque: 8～12N.m

2-32
13）Check the water inlet cover and gasket for wear. Replace it if necessary. 15）Remove the right crankcase cover.

WATER PUMP GEAR

14）Unscrew and remove water pump gear. 16）Remove the water pump gear.

2-33
17）Check the water pump gear and O-ring for wear, replace them if necessary.

O-RING

2-34
 2.5.2 Troubleshooting to Crankcase

Description Damage Form Trouble Symptom of Component Trouble Symptom of Motorcycle Remedy

Cracks on the crankcase Oil leakage through crankcase Repair or replace

Threads on the crankcase are Oil leakage between RH/LH Repair or replace
damaged crankcases
Gas leakage between cylinder head Engine fails or is hard to start. Trim the threaded hole or replace the
Crankcase Threads of cylinder are damaged and cylinder due to loose of Engine lacks power. Unstable idle crankcase
cylinder nuts speed
Bolt of cylinder is broken Do. Do. Replace the broken bolt with a new
one
Oil seal is damaged Oil leakage through oil seal Replace the oil seal
Damaged or cracks on the right Oil leakage through right crankcase Repair or replace right crankcase
Right Crankcase crankcase cover cover cover
Cover Gasket is damaged Oil leakage between right crankcase
Replace the gasket with a new one
and cover
Damaged or cracks on the left Oil leakage through left crankcase Repair or replace left crankcase
Left Crankcase crankcase cover cover cover
Cover Gasket is damaged Oil leakage between left crankcase
Replace the gasket with a new one
and cover
Water Pump
Water pump gear is damaged Coolant liquid fails to cycle Engine overheats Replace water pump gear
Gear
Water Inlet
Gasket is damaged Water leakage Replace the gasket with a new one
Cover & Gasket
O-Ring of Water
O-ring is damaged Water leakage Replace the O-ring
Pump Gear

2-35
 2.6 CRANK MECHANISM
2.6.1 Removal, Maintenance and Installation
1）Check the mainshaft bearings, countershaft bearings and crankshaft bearing. 3）Remove the crankshaft and connecting rod. Check the timing drive gear for
Replace them if necessary wear. Replace the worn-out gear with a new one. Note: The “O” mark of timing
drive gear should be aligned with crank woodruff groove.
TIMING DRIVE
GEAR

2 ） The construction of crankshaft, mainshaft comp., countershaft comp., 4）The construction of connecting rod is shown as following figure. Measure
gearshift drum, forks, etc. is shown as following figure. the gap of connecting rod big end. If it is out of the service limit, replace the
connecting rod.
Service limit of radial play: 0.05mm Service limit of axial play: 0.60mm

2-36
5）Check the timing drive gear of crankshaft for wear. Replace it if necessary. 7）Measure the O.D. of the piston pin with a micrometer. If it is beyond the
service limit, replace the worn pin with a new one.
Service limit: 14.95mm

TIMING DRIVE GEAR

6）Check LH/RH bearings of crankshaft and balance shaft for wear. Replace 8）Clear away carbon deposit on the piston top.
them if necessary.

BALANCE
SHAFT

2-37
9）Remove the piston rings from the piston. Check the piston rings for wear and
elasticity. Measure the opening gap of the rings with a feeler gauge. If it is Measure the diameter of piston skirt at the position which is 10mm away from
beyond the limit, replace the piston ring as a set. the bottom. If it is beyond the limit, replace the piston.
(Limit value: RingⅠ&Ⅱ: 0.5mm O-ring: 1.2mm) Service limit: ＜Φ 63.3mm

10） Measure the width of piston groove and diameter of piston skirt. If it is
beyond the limit, replace the piston. Limit value of the ring: 0.85mm

2-38
 2.6.2 Troubleshooting to Crankshaft Mechanism

Trouble Symptom of
Description Damage Form Trouble Symptom of Vehicle Remedy
Component
Carbon deposit on the piston top Engine overheats Clear away carbon deposit
Carbon deposit in the piston ring The piston ring is seized in the Engine fails or is hard to start. Engine lacks Do.
groove ring groove power. Thick blue smoke from the exhaust pipe
Scuffing or scratches on the surface Piston-to-cylinder clearance is Do. Replace the piston
of piston skirt too large
Piston Do. Do.
Seriously worn piston Do.
Piston ring-to-groove clearance Do.
Seriously worn piston ring groove Thick blue smoke from the exhaust pipe
is too large
Piston pin-to-hole clearance is Knocking sound of piston pin and of cylinder Do.
Excessively worn piston pin hole
too large
Radial and axial gap is too Knocking sound of big end bearing Replace the crankshaft/
Crank pin Worn out
large connecting
Excessive wear of needle bearing Do. Do. Do.
Bearing Excessive wear or damage of Abnormal sound from the crankshaft bearing Replace the bearing
crankshaft bearing
Engine fails or is hard to start. Engine lacks Replace the rings as a set
Piston ring is broken
power. Thick blue smoke from the exhaust pipe
Piston ring is seriously worn End or side gap is too large Do. Do.
Piston Ring Piston ring is out of elastic Improper air-tightness of Do. Do.
piston-to-cylinder
Piston ring end gaps are not Engine lacks power. Thick blue smoke from the
Improper placing Offset the piston ring end gaps
staggered exhaust pipe
Piston pin-to-hole clearance is Piston pin slap Replace the piston pin
Piston pin Excessive wear
too large
Piston pin-to-small end hole is Replace the connecting rod
Excessive wear of small-end hole Do.
too large
Connecting
Connecting rod is bent Knocking of cylinder Do.
rod
Radial and axial gap is too Knocking sound of big-end bearing Do.
Excessive wear of big-end hole
large

2-39
 2.7 STARTERS
2.7.1 Kick-starter
 1 Removal, Maintenance and Installation 3）Check the torque spring of starting for elasticity, and replace the spring if
1）Remove the crankshaft & connecting rod comp. necessary. For which purpose, remove the spring, ring and seat of starting
shaft.

2）Remove the starting shaft, and check it for wear. Replace it if necessary. 4）Remove the washer III and ratchet seat of starting shaft, and check them for
wear. Replace them if necessary.

WASHER Ⅲ

2-40
5）Remove the circlip, and check it for deformation. Replace it if necessary. 8）Remove the snap ring of starting shaft, and check it for deformation. Replace
it if necessary.

6）Remove the friction spring of starting gear, and check it for elasticity. 9）Remove the ratchet, and check it for wear. Replace it if necessary.
Replace it if necessary.

2-41
2.7.2 Troubleshooting to Kick-starter
Trouble Symptom of
Description Damage Form Trouble Symptom of Vehicle Remedy
Component
Starting Spline connected with starting Starting lever slipping Starting is slipping Replace the starting lever with a
lever lever slipping new one
Starting Gear is worn Starting is slipping Starting is slipping Replace the gear with a new one
gear Gear is damaged Starting is hard
Ratchet is worn heavily Starting is slipping Starting is slipping Replace the ratchet with a new
one
Ratchet
Friction spring of starting gear Starting is slipping Starting is slipping Replace the spring with a new
is broken one
Spline of starting shaft is Starting is slipping Starting is slipping Replace the starting shaft with a
Starting
damaged new one
shaft
Return spring is broken Starting lever fails to return Replace the return spring

2-42
2.7.3 Electric starter
 1 Removal, Maintenance and Installation
1）Unscrew the fixing bolt of starting motor. 3）Unscrew bolts of left crankcase cover. (Tightening torque: 8～12N.m)
(Bolt specification M6×28 Tightening torque: 8～12N.m)

4）Unscrew bolts of mid gear cover, and remove the cover. Check the O-ring of
2）Knocking with a plastic hammer, remove the starting motor. cover, replace it if necessary. (Replace the O-ring if it is damaged or creased,
otherwise there will be oil leakage)

MID GEAR

O-RING

2-43
5）Remove the dual-gear comp. I, a washer, dual-gear shaft and a washer in due 7）Remove the magneto wire plate from the left crankcase cover.
succession. Check them for wear. Replace the worn part.

6）Remove the gear indicator, and check it. Replace or repair it if necessary. 8）Remove the left crankcase cover comp., and check the gasket of cover.
Replace the gasket if necessary.

2-44
9）Remove the dual-gear II, and check it for wear. Replace it if necessary. 11）Check the starting clutch body, rollers and springs for wear. Replace
the worn part if necessary.

10）Unscrew bolt of magneto, remove the rotor of magneto with specified tools.
(Bolt specification M10×35 Tightening torque: 40～50N.m) 12）Check the needle bearing of dual-gear II for wear. Replace the worn
part.

NEEDLE BEARING

2-45
13）Check the coils of both rotor and stator of magneto for damage. Replace the
damaged part.

2-46
2.7.4 Troubleshooting to Electric Starter

Trouble Symptom of Trouble Symptom of

Description Damage Form Remedy
Component Vehicle
Carbon brush is worn heavily Starting motor lacks Replace the worn brush
power or is out of work
Spring of carbon brush is broken Starting motor lacks Replace the spring
or is out of elasticity power
Armature commutator surface is Do. Clean the commutator surface with gasoline or alcohol
fouled
Starting Armature commutator surface is Do. Polish the surface of commutator with fine abrasive
spotted, burnt or damaged paper. Make the cut on the mica plate between each
motor commutator piece with broken saw bit 0.5-0.8 mm
deeper than the commutator surface. Remove the chip
and burr between each commutator
Armature commutator surface is Starting motor lacks Replace the starting motor
worn considerably power or is out of work
Rotor coil is damaged by short Starting motor is out of Replace the starting motor
circuit or broken circuit work
The contact surface of starting Starting clutch is Starting clutch is slipping Replace the gear of starting clutch
clutch and roller is damaged or slipping or has or has abnormal sound
worn heavily abnormal sound
Starting The contact surface of starting Replace the starting clutch
clutch clutch and roller is worn into Do. Do.
concave groove
The roller is worn heavily or Replace the starting clutch
Do. Do.
damaged

2-47
 2.8 LUBRICATION SYSTEM
 2.8.1 Removal, Maintenance and Installation
1）Unscrew the oil gallery bolt from the cylinder head. 3）Unscrew and remove the locknut M8 of cylinder head.
(Bolt specification: M6×12 Tightening torque: 8～12N.m) (Tightening torque: 30～40N.m)

OIL GALLERY BOLT

2）Unscrew and remove the bolt of valve cover, then remove the valve cover. 4）Unscrew and remove the bolt of cylinder head connecting
(Bolt specification: M6×12 Tightening torque: 8～12N.m) （Bolt specification: hexagon socket head, M6×90
Tightening torque: 8～12N.m）

2-48
5）Dismantle the cylinder block, and check the oil gallery in the cylinder block 7）Remove the oil screen cap M36×1.5 from the crankcase.
for clogs. (Tightening torque: 20～30N.m)

6）Check the oil gallery in the crankcase, and clean it. 8）Check the oil strainer, and clean it if necessary. Replace the damaged part if
necessary.

OIL STRAINER

2-49
9）Unscrew the drain plug, empty the engine. Check the oil gallery and clean it 11）Check the oil sight glass for leakage, and replace it if necessary. Check the
if necessary. oil gallery in the right crankcase cover for foreign matter, and clean it.

OIL GALLERY

10）Unscrew the bolts of right crankcase cover, then remove the right crankcase
12）Remove the clutch lifter rod and push rod. Check them for deformation
cover. (Tightening torque: 8～12N.m)
and replace deformed part.

2-50
13）Remove the bearing, and check it for deformation. Replace it if necessary. 15）Remove the oil pump gear, then check it for wear and flexible turning.
Replace it if necessary.

14）Turning the driven gear of oil pump, check the oil pump for proper 16）Measure the gap between the inner rotor and outer rotor. Replace the oil
functioning. Replace the pump if it is out of work.. pump if it is out of the service limit. Service limit: 0.075~0.165

2-51
17）Check the oil gallery in the oil pump for clogs or foreign matters. Clean it if
necessary.

2.8.2 Troubleshooting to Lubrication System

Trouble Symptom of
Description Damage Form Trouble Symptom of Vehicle Remedy
Component
Inner/outer rotor of oil pump Oil is delivered improperly by Engine lacks power, overheat, Replace the oil pump
Oil pump
is worn heavily the oil pump or excessive wear
Oil is delivered improperly by Engine lacks power, overheat, or Clean the oil strainer
Oil strainer Strainer is clogged
the oil pump excessive wear
Engine lacks power, or
Lubrication system Oil gallery is clogged Insufficient oil supply overheats. Parts are damaged Clean the oil gallery
heavily

2-52
 CHAPTER 3 CHASSIS

3.1 FRAME BODY

3.1.1 Motorcycle identification
1) VIN
The vehicle identification number (VIN) is stamped 3.1.2 Maintenance of Frame
into the left of steering stem.
Damage
Description Trouble Symptom Remedy
From
Frame is
Frame deformed or Running off-tracking Correct or replace
： broken
Deformed or Replace the side
Effect of parking
broken stand
Side stand
Return spring Side stand fails to return.
VIN Replace the spring
is damaged Effect of parking
1.2 Nameplate
Nameplate is fixed in front of the steering stem. Covering Replace or repair
Broken Effect of appearance
parts the covering parts

Fender Damaged Effect of fending Replace the fender

Decrease of riding
Seat Broken Replace the seat
comfort

Deformed or Step bar is deformed or

Footrest Correct or replace
broken rubber is broken
Nameplate

3-1
3.1.3 Maintenance of Frame and Accessories
 Removal, Maintenance and Installation 3） Check the free play of rear brake pedal to see if it is out of the service limit.
1）Check the frame and accessories. Repair or replace if necessary. If it is, exhaust the air in the rear brake system and check the free play of rear
brake pedal again to make sure it is within the limit.
Free play of rear brake: 20-30mm

REAR BRAKE PEDAL

2）Check the rearview mirror for proper fastening. Tighten it and wipe the
surface. 4） Check the front fender for damage. Replace it if necessary.
REARVIEW
MIRROR
FRONT FENDER

3-2
5) Check the rear fender for damage. Replace it if necessary. 7) Check the pillion footrest for wear. Replace it if necessary.

REAR FENDER PILLION FOOTREST

6) Check the main footrest for wear. Replace it if necessary. 8) Check the side stand for deformation. Replace it if necessary

MAIN FOOTREST SIDE STAND

3-3
9) Check the pillion rail for damage. Replace it if necessary. 11) Check the fuel tank for leakage. Replace it if necessary.
PILLION RAIL FUEL TANK

10) Check the seat for break. Replace it if necessary. 12) Check the right side cover for damage. Replace it if necessary.
RIGHT SIDE COVER
SEAT

3-4
13) Check the left side cover for damage. Replace it if necessary. 15) Check the left ornament of fuel tank for break. Replace it if necessary.
LEFT SIDE COVER LEFT ORNAMENT

14) Check the right ornament of fuel tank for break. Replace it if necessary.
RIGHT ORNAMENT

3-5
 3.2 SUSPENSION SYSTEM
 3. 2.1 Removal, Installation and Maintenance of Steering Handle
1）Turning the steering handle, check it for proper functioning. 3）Unscrew the fixing bolt of steering stem top bridge.

2）Remove the steering handle, check it for deformation. Correct or replace it if 4）Unscrew adjusting nut from the steering stem and remove the lower bridge.
necessary.

3-6
5）Check the top/bottom race of steering stem upper bearing for wear. Replace 7）Before installing the steering stem, apply a layer of grease to bottom race of
them if necessary. the bearing.

6）Extract the steering stem and check it for wear or deformation. Replace it if 8）Tighten up the locknut of steering stem.
necessary. （Nut specification: M24×1 Tightening torque: 60-90N·m）

3-7
●3.2.2 Troubleshooting to Steering Stem and Accessories

Description Damage Form Trouble Symptom Remedy

Turn the adjusting nut by means of a

The bolt of steering stem Operation of steering handle wrench until the steering stem moves
is over tighten is stiff. smoothly and easily, and no radial play
Bottom Race between the steering and pipe is allowed
of Bearing The race is worn
Steering handle shakes or
seriously. Such defects
vibrates. Steering handle Replace the bottom race of bearing as a set
as pockmarks, dints,
runs stiffly
cracks are found
Steering handle shakes or
Cone bearing is worn,
Bearing vibrates. Steering handle Replace the bearing
deformed or damaged
runs stiffly
Steering
Deformed Replace the steering stem
Stem

3-8
 3.3 FRONT SUSPENSION
 3.3.1 Removal, Installation and Maintenance of Front Shock Absorber
1）Unscrew the bolt of top bridge and steering bar. 3））Unscrew the locknuts of front axle. Remove the front axle and front wheel.

2）Unscrew the bolt of bottom bridge. 4）Unscrew the mounting bolt from front fender. Remove the front shock
absorbers.

3-9
5）Remove the drain bolt, empty the damping oil from the pipe. Check the oil, 7）Remove the oil seal, check it for wear. Replace it with a new one if necessary.
and replace it if necessary.

6）Remove the dust seal, circlip, bottom case, etc. 8）Remove the rebound spring, and check it for wear. Replace it if necessary.

3-10
9）Measure the I.D. (Φ 37) of bottom case. Replace it if it is out of the limit. 11）Measure the free length of damping spring. Replace it if it is out of the
Service limit: 37.5mm service limit. Free length of spring: 410±2 mm

FREE LENGTH OF SPRING

10）Measure the damping spring and replace it if it is out of the limit. 12）Pour 320±2ml of the recommended damping oil into the pipe
Service limit: 8mm

3-11
3.3.2 Troubleshooting to Front Shock Absorber

Description Damage Form Trouble Symptom Remedy

The spring is non-elastic or Front shock absorber is too soft or abnormal

Spring Replace the fork spring
damaged sound comes out the bottom case

Bending or deformed Off-track in running Correct or replace the part

Working surface is damaged or

Fork tube Oil leakage through seal Replace the fork tube
scratched

Chromium-plated part is worn to

Oil leakage through seal Replace the fork tube
expose the substrate

Bottom case Broken, deformed or damaged Oil leakage through bottom case Replace the bottom case

Heavily worn or damaged Shock absorber is too soft Replace the ring
Damper rod

Ring is heavily worn or damaged Shock absorber is too soft Replace the ring

Oil seal Heavily worn, damaged or aged Oil leakage from front shock absorber Replace the oil seal

Damping oil Lack of oil Shock absorber is too soft Fill damping oil as per the specification

3-12
 3.4 REAR SUSPENSION
 3.4.1 Removal, Installation and Maintenance of Rear Shock Absorber
1）Check rear fork to see if it swings. Replace the rear fork shaft sleeve if
necessary. 3）Remove the rear fork shaft.

2）Unscrew the locknut of rear fork shaft. 4）Check the rear fork shaft sleeve for wear. Replace the rear fork if necessary.

3-13
5）Unscrew the upper and lower connecting bolt of rear shock absorber. Check 3.4.2 Troubleshooting to Rear Suspension
the bush for wear. Replace it if necessary.
Description Damage Form Trouble Symptom Remedy

Spring is weak or Rear shock absorber is Replace the

broken too weak or stiff spring
Oil leakage from Rear shock absorber is Replace the rear
Rear Shock
rear shock absorber too weak shock absorber
Absorber
Piston rod is bended, Rear shock absorber is Replace the rear
deformed or broken too stiff shock absorber

Correct or
Off-tracking in
Deformed replace the rear
running
Rear fork fork
6）Check the spring for functioning. Check the rear shock absorber for leakage.
Broken Weld or replace
Replace the shock absorber if necessary. It fails to operate
the part

3-14
 3.5 FRONT AND REAR WHEELS
 3.5.1 Removal, Installation and Maintenance
1）Unscrew the locknut of front hydraulic brake. Remove the hydraulic brake. 3）Check the speed sensor for wear. Replace it if necessary.

2）Unscrew the locknut of front axle, and remove the front wheel. 4）Remove front axle bush and check it for wear. Replace it if necessary.

3-15
5）Remove the oil seal of front axle and check it for wear. Replace the oil seal if 7）Unscrew the adjusting nut of chain. Remove the chain.
necessary.

6）Check the bearing of front axle for wear. Replace it if necessary. 8）Unscrew the locknut of rear axle and extract rear axle

BEARING

3-16
9）Remove the right bush of rear axle. Check it for wear. Replace it if necessary. 11）Remove the bolt M8 on the rear driven sprocket and remove the circlip.
Check it for wear and replace it if necessary.
Tightening torque: 24-30Ｎ·m

10）Remove the left bush of rear axle. Check it for wear. Replace it if necessary. 12）Check the depth of wheel tread. Replace the tire if the depth is less than
2mm.

3-17
13）Check the oil seal of rear axle. Replace it if necessary. 15）Check the mounting surface of brake disc. Replace the wheel hub if
necessary.

OIL SEAL
14）Check the bearing of rear axle for wear. Replace it if necessary. MOUNTING SURFACE OF BRAKE DISC
16）Check the brake disc for wear. Replace the brake disc if necessary.

Front brake disc Rear brake disc

BEARING

3-15
17) Exhaust the air in the front brake after assembly. 19) Exhaust the air in the rear brake after assembly.

18) At last, pull and loosen the front brake lever. Repeat this action for 10 times. 20）At last, step and loosen the rear brake pedal. Repeat this action for 10 times.
Adjust the control force to the degree which is proper for users. (Less than Adjust the control force to the degree which is proper for users. (Less than
200N) 350N)

3-16
3.5.2 Troubleshooting to Front and Rear Wheel
Description Damage Form Trouble Symptom Remedy

Speed sensor is damaged Pointer of odometer doesn’t turn Replace the speedometer

Front Wheel Oil seal of front axle is worn Too much dirt in the oil seal of front axle Replace the oil seal of front axle
Exhaust the air in the front hydraulic brake. See
Poor braking performance Wear braking effect of front hydraulic brake
point 16 of 5.2 for detailed steps.
Oil seal of rear axle is worn Too much dirt in the oil seal of rear axle Replace the oil seal of rear axle
Rear Wheel Exhaust the air in the rear hydraulic brake. See
Poor braking performance Wear braking effect of rear hydraulic brake
point 17 of 5.2 for detailed steps.

3-20
 3.6 INTAKE SYSTEM AND EXHAUST SYSTEM

 3.6.1 Removal, Installation and Maintenance of Intake System 3）Remove the element of air filter. Check it for damage. Replace it if necessary.
1）Open the seat lock.. Disassemble the seat.

2）Unscrew the screw of air filter cover. Remove the air filter cover and check it. 4）Check the air filter housing and clean the dirt. Replace it if necessary.
Replace it if necessary.

3-21
3.6.2 Trouble Shooting to Air Filter

Description Damage Form Trouble Symptom Remedy Remark

Too much dust deposited Engine is hard to start. Engine lacks Remove the element according to 3.6.1. Clean it Never use water, gasoline
on the element power. Unstable idle speed. Excessive in cleansing solvent and dry it up. Then soak the or low flash point solvents
fuel consumption. Thick blue smoke clement in engine oil SAE15W/40-SE until it for cleaning the air cleaner
Air Filter from the exhaust pipe. becomes saturated, and then squeeze extra oil.
At last, install the element to initial position
The element is fractured Noise from the air suction of engine is
Replace the damaged element
too loud

3-22
 3.6.3 Removal, Installation and Maintenance of Exhaust System
1）Unscrew locknut of exhaust pipe. 3）Remove the exhaust pipe. Check the muffler and mounting bracket for
damage. Replace or repair if necessary.

2）Unscrew bolt of muffler. 4）Remove the gasket of muffler, and replace it with a new one.

3-23
5）Shaking the muffler, check it for abnormal sound. Replace it if necessary.

3.6.4 Maintenance of Exhaust Muffler

Description Damage Form Trouble Symptom Remedy Remark

Gasket is broken Replace the gasket with a new Replace the gasket
Gasket Noise from the exhaust pipe is too loud one whenever the ex. pipe
is disassembled
The muffler case or mounting Replace the exhaust muffler
Exhaust Muffler Do.
bracket is damage
Sealing-off is found on the part Abnormal sound from the inside of Replace the exhaust muffler
Exhaust Muffler
exhaust muffler
Carbon deposit in exhaust pipe Clean away carbon deposit in
Exhaust Muffler Performance of engine is poor exhaust pipe with genuine
cleansing solvent

3-24
 3.7 COOLING SYSTEM
 3.7.1 Removal, Installation and Maintenance of Cooling System
1）Open the seat lock.. Remove the seat. 3）Unscrew the mounting screw on the right ornament of fuel tank. Remove
the right ornament of fuel tank.
Mounting screw

2）Unscrew the mounting screw on the left ornament of fuel tank. Remove the
left ornament of fuel tank.
Mounting screw 4）Unscrew the mounting screw of radiator cowl. Remove the radiator cowl.

3-25
5）Remove the fuel tank. 7）Unscrew the mounting bolt M6×22 of radiator.

6）Remove the hoop of water pipe. 8）Remove the radiator and check it for damage or clog. Replace it if necessary.

3-26
9）Check the water pipe for damage and aging. Replace it if necessary. 3.7.2 Troubleshooting to Cooling System.

Damage
Description Trouble Symptom Remedy Remark
Form
Too much dirt,
coolant liquid, no Clean the
Clogged circulation about radiator or
coolant liquid, replace it
Radiator
engine overheats
No circulation about
Replace the
Damaged coolant liquid,
radiator
engine overheats
Aged, Replace the
Water pipe Water leakage
damaged water pipe
Water Replace the
10）Check the water reserve tank for damage or leakage. Replace it if necessary. Water reserve
leakage, Water leakage water reserve
tank
damaged tank

3-27
 CHAPTER 4 ELECTRICAL COMPONENTS AND METER
●Configuration of Electrical Components on the Vehicle

HEADLIGHT
CLUTCH SW. LEFT HANDLE BAR SW. FLASHER RELAY TAILLINGT
FR. POSITION LIGHT

RR. WINKER
FR. WINKER

LICENSE PLATE LIGHT

FAN

STARTING RELAY

BATTERY

STARTING MOTOR
SPEED SENSOR MAGNETO & GEAR WATER TEMPERATURE FUSE
SWITCH SENSOR

4-1
 DIAGNOSE INTERFACE
FOR EFI RESERVED INTERFACE FOR
FUEL PUMP & FUEL
BURGLAR ALARM IGNITION SW. METER
EFI CONTROLLER SENSOR

RECTIFIER

HANDLEBAR SW., RH

RR. BRAKE SW.

FR. BRAKE SW.

SPARK PLUG IGNITION COIL HORN

4-2
●ELECTRIC DIAGRAM

4-3
 4.1 CHARGING SYSTEM
4.1.1 ●The charging system consists of:
1）Battery(12V9Ah)
2）Magneto: AC permanent-magnet generator, magneto rotor and stator (including charging/lighting coil and exciter coil).
3）Rectifier with regulator: is of three-phases, full-wave switch type.
4）Fuse: chip fuse 20A, with a spare one.
The battery is connected with the magneto in parallel, and to the electric equipment with power.
4.1.2 ●Charging system is designed to supply the devices with power at the electric power that generator send out is enough, and charge toward the battery for
storing a part of electric power. Therefore, make sure to supply the device with electric power when the generator runs at a lower speed or power is weak due heavy
load.
4.1.3 ●Removal, Installation and Maintenance of Charging System
Turn the key from to to open the ignition switch. Turn the

stop switch to

Disconnect the rectifier coupler from the main cable, check

them for continuity. Replace the rectifier if necessary.

RECTIFIE

STOP SW.
IGNITION SW.

SOCKET OF RECTIFIER
AND MAIN CABLE SOCKET OF MAGNETO
AND RECTIFIER
4-4
 Charging coil coupler Y/Y/Y wire
The charging voltage of rectifier is within 13V～15V. If it is less
is charging/LIGHTING coil
than 13V, and the malfunction is determined from the rectifier, replace
the part with a new one.
Disconnect the connection between rectifier and charging coil from
magneto; check the lighting coil for continuity. If not so, repair or replace
it.

Start the engine, measure the voltage between Y wire to W wire of charging/light coil with multimeter (A.C. 200V). The voltage of charging/lighting coil
without load is: when rotate speed of engine changes within the scope of 1500 r/min～8000 r/min, the voltage between Y wire to Y wire of charging/light coil
without load should be in the scope of 20±5 V～100±20 V. The voltage increases with the increase of the rotate speed.
The voltage will be different from the normal valve considerably if a short circuit or broken circuit occurs on the charging/lighting coil, or the coil is connected
with the metal housing. Replace the charging/lighting coil if necessary.
Remove the flywheel of magneto rotor and check it for
Replace the magneto rotor if the no-load voltage is
magnetism. Replace it if necessary.
different from the normal valve considerably

4-5
Check the voltage of battery. If it is below 12V, recharge the battery.

Check the fuse for continuity. Replace the blown fuse. Specially pay attention
to use of the same specification fuse. Never use other material such as
aluminium, iron or copper with instead.
Speciation of fuse: 20A

FUSE BATTERY

4.1.4 Troubleshooting of Charging System

Description Damage From Trouble Symptom Remedy

A broken circuit occurs on the Output voltage of coil is low. Charging to battery is
Replace the charging/lighting coil
Magneto charging/lighting coil insufficient
Charging/lighting coil is broken（the The coil has no output voltage. The battery power is
Replace the charging/lighting coil
resistance is ∞） insufficient, and electric components are out of work

Rectifier
Charging to battery is insufficient. Light is dim. The current
with The rectifier is faulty Replace the rectifier
is too high, and the battery is deformed.
Regulator

The battery is damaged Starting motor fails to run Replace the battery
Battery Shortage of electrolyte due to long-term The starting motor fails to run or runs slowly. The signal Charging to battery or replace the
storage system is out of work battery

4-6
 4.2 EFI SYSTEM
4.2.1 Working principal

● EFI system including the following parts in the table.

Part Name Major component and explanation Mounting position and description
ECU controller Computer program, chip, electronic components, circuit board On the Vehicle
Throttle valve body Throttle body, throttle position sensor (TPS) Outside the intake valve of cylinder head
Oxygen sensor Used for closed-loop control On the muffler
Engine temperature sensor To measure the engine temperature On the cylinder head, cylinder block, or high
temperature water passage.
IAT sensor To measure the air inlet temperature On the air filter
Intake pressure sensor To measure the air inflow On the Vehicle
Fuel pump To generate the necessary high-pressure fuel On the Vehicle
Fuel injector To inject fuel On the air inlet pipe of engine
Idle air control valve (IACV) To compensate engine idle air intake On the Vehicle
EFI main relay Special-purpose components for EFI system On the Vehicle
Ignition coil Inductance type ignition coil On the engine
Magneto Including 36-2 teeth magnet steel, coil and rotation speed sensor On the engine
Spark plug Spark plug type: CPR8EA, standard valve of contact clearance: On the engine
0.85~0.95mm。

4-7
1. ECU controller

A向
A direction
（1）ECU照片、外形、针脚
PICTURE, APPEARANCE AND

STINCH OF ECU

FRONT VIEW OF ECU PLUG

A(A向)
direction
21

ECU is the control center of the entire EFI system. It is mounted on the vehicle. It determines the optimum injection time, injection quantity and ignition advance
angle through the analysis and process about intake pressure sensor, engine temperature sensor, intake temperature sensor, engine rotation speed sensor, throttle
position sensor (TPS) and oxygen sensor. Working condition of ECU: supply range DC 10～14V, ambient temperature -25℃～85℃
● Note: Don’t charged inserted ECU controller
Disassembly of ECU is forbidden. Don’t pry the pin in the plug socket with hard matter.
Avoid bastinado or collision to ECU. Water or oil is forbidden to contact the ECU or its connector.

2. Throttle valve body

AIR FILTER AIR INLET PIPE

4-8
 It consists of throttle position sensor (TPS), throttle valve body, and adjusting screw of air volume. And it is mounted between air inlet pipe and air filter.
Note: please clean throttle valve body regularly to make the system reach the best performance.
3. Oxygen sensor
OXYGEN SENSOR

MUFFLER

The oxygen sensor is mounted on muffler. It is used to detect the oxygen content in the exhaust gas from the engine and to realize closed-loop control and
self-adaptation control of the system.

● Note: Knocking or colliding to the sensor is forbidden.

Washing the oxygen sensor with water is forbidden when the engine is heat.
4. Engine temperature sensor

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 Engine temperature sensor is mounted on the engine cylinder block. It is used to detect engine temperature.
5. Intake air temperature sensor (IAT)

IAT

Intake air temperature sensor is mounted/connected on the air filter or the position close to the filter. It is used to detect intake air temperature.
6. Intake pressure sensor

INTAKE PRESSURE SENSOR

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Intake pressure sensor is used to detect the negative pressure of engine. It is connected with rubber pipe and air inlet pipe of engine.
● Note: No water, oil or other impurity in the intake pressure sensor. Make sure good sealing ability of joint.

7. Fuel pump, EFI main relay

FUEL PUMP (Mounted on the bottom of fuel tank）

EFI MAIN RELAY

EFI system is powered by an EFI main relay. The fan is powered by another EFI main relay. And the two EFI main relays are controlled by ECU controller. If there’s
no power about EFI system or fan, please check the connector about main cable and EFI main relay for poor contact or check the function of EFI main relay.
● Note: Keep the fuel pump body and fuel port clean.
8. Injector

INJECTOR

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9. Idle air control valve
AIR OUTLET

AIR INLET

It is used to compensate the air inflow at the engine idle condition by connecting with rubber pipe and air inlet pipe of engine.

● Note: Direction of airflow

Make sure good sealing ability of joint.

10. Ignition coil

IGNITION COIL

It is inductance type ignition coil with strong ignition energy.

● Note: Replace with the same type of ignition coil only.

11. Magneto

It consists of rotor with 36-2 teeth, stator and rotation speed sensor.
● Note: Replace with the same type of rotor, stator and rotation speed sensor only.

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 Make sure that the clearance between rotor and rotation speed sensor is 0.7～1mm.
12. Spark plug

Spark plug type: CPR8EA, standard valve of contact clearance for spark plug is 0.85~0.95mm.
4.2.2 Removal, Maintenance and Installation of EFI
EFI FAULT INDICATING LIGHT
1. Basic principle of fault diagnosis
1） Fault message record
ECU detects the sensors, relevant circuits, fault indicating light, battery voltage and even ECU itself constantly. And it checks the reliability of output signals,
internal signals from the sensor. Once the fault is found, ECU will record the fault message at the memorizer of chips.
2）Fault type: short circuit, broken circuit, lost of signal
3）Failure warning: There’s fault indicating light on the meter, so almost all sensors on the EFI system can be detected. If fault is detected, the fault light will be
lightened to warn until the fault is handled.
4）When open the key switch but didn’t start the engine, the fault light will be lighten for 2~3 seconds. If there’s no fault, the fault light will be extinguished.
Otherwise, the fault light will glitter according to the codes (see below table):
Type of sensor Coding

Throttle position sensor 22 (2 short 2 long )

Intake pressure sensor 23 (2 short 2 long )

Oxygen sensor 24 (2 short 4 long )

Cylinder block temperature sensor 32 (3 short 2 long )

Air temperature sensor 33 (3 short 3 long )

System voltage 34 (3 short 4 long )

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2. Troubleshooting: Maintenance steps
First: Maintenance according to fault code from the fault light: S/N Steps Result Subsequent steps
1）Maintenance of throttle position sensor 1 Open the key switch, run the fuel pump Next step
for 3 seconds by listening (by touching is
also ok)
2 Extract the sensor plug on the cable. YES Next step
Check with multimeter to see if the
1. Fault code 22----throttle position sensor voltage between No.2 and No.3 stitches is NO 5
The figure on the right is the electric diagram 5V.
Connect No.1 stitch to ECU No. 25 stitch 3 Check with multimeter to see if the YES Next step
Connect No.2 stitch to ECU No. 13 stitch resistance value between No.2 and No.3 NO Replace the sensor
Connect No.3 stitch to ECU No. 26 stitch stitches is about 5KΩ .
4 Turn the throttle position sensor from one YES Replace the sensor
Stitches: THROTTLE POSITION side to another side gently. At the same NO Replace the ECU
1----output angle signal SENSOR time, check with multimeter to see if
2----sensor ground there’s short circuit or broken circuit
3----power source 5V between No.1 and No.3 stitches or if the
resistance value changed dramatically.
5 Check with multimeter to see if there’s YES Repair or replace
short circuit or broken circuit between the cable
No.13, 25, 26 and No.1, 2, 3 stitches. NO Replace the ECU
2）Maintenance of pressure sensor
Maintenance steps
S/N Steps Result Subsequent steps
2. Fault code 23----pressure sensor 1 Open the key switch, run the fuel pump for Next step
The figure on the right is the electric diagram 3 seconds by listening (by touching is also
Connect No.1 stitch to ECU No. 26 stitch ok)
Connect No.2 stitch to ECU No. 12 stitch 2 Check to see if the connection between YES Next step
Connect No.3 stitch to ECU No. 23 stitch sensor plug and cable plug is good.
NO Repair or replace
Stitches:
the plug
1----power source 5V 3 Extract the sensor plug on the cable. Check YES 5
2----output pressure signal with multimeter to see if the voltage NO Next step
3----sensor ground between No.1 and No.3 stitches is 5V.
4 Check with multimeter to see if there’s short YES Repair or replace
circuit or broken circuit between No.12, 13, the cable
26 and No.1, 2, 3 stitches. NO Next step
5 Replace the pressure sensor to see if the YES Replace the sensor
fault has been handled. NO Replace the ECU

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 Maintenance steps
3）Maintenance of oxygen sensor S/N Steps Result Subsequent steps
1 Open the key switch, run the fuel pump for 3 Next step
seconds by listening (by touching is also ok).
Start the engine.
2 Extract the sensor plug on the cable. Check YES Next step
with multimeter to see if the voltage between NO 4
3. Fault code 24----oxygen sensor
No.3 and No.4 stitches is 12V.
The figure on the right is the electric diagram
3 Check with multimeter to see if the YES Replace the ECU
Connect No.1 stitch to ECU No. 24 stitch
resistance value between No.3 and No.4 NO Next step
Connect No.2 stitch to ECU No. 13 stitch
stitches is about 6~25Ω .
Connect No.3 stitch to power output (12V) of 4 Check with multimeter to see if there’s short YES Repair or replace
fuel pump relay circuit or broken circuit between No.3 stitch the cable
Connect No.4 stitch to vehicle ground wire and power output (12V) of fuel pump relay; NO Next step
(green) and between No.3 stitch and vehicle ground
wire (green).
5 Insert the oxygen sensor plug on the cable. Next step
Set it to neutral gear. Start the engine and
make it in idle speed till the cylinder
temperature is about 80℃.
6 Extract the sensor plug on the cable. Check YES Next step
with multimeter to see if there’s voltage
output (0.1~0.9V) between No.1 and No.2 NO Replace the sensor
stitches.
7 Check with multimeter to see if there’s short YES Repair or replace
circuit or broken circuit between ECU the cable
4）Maintenance of cylinder temperature and air temperature sensor No.13, 24 and sensor No.1, 2 stitches. NO Replace the ECU

Maintenance steps
S/N Steps Result Subsequent steps
1 Open the key switch, run the fuel pump for 3 seconds by listening (by Next step
touching is also ok). Start the engine.
2 Check with multimeter to see if the resistance value between No.1 and YES Replace the ECU
No.2 stitches corresponds with the temperature (refer to the related part NO Next step
in this service manual).
3 Check with multimeter to see if there’s short circuit or broken circuit YES Repair or replace the cable
between ECU No.11, 13, 23 stitches and their corresponding stitches on NO Replace the ECU
the sensor.

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5）Test of system voltage
4. Fault code 34----system voltage
Maintenance steps
S/N Steps Result Subsequent steps
1 Check with multimeter to see if the voltage between YES Next step
positive and negative terminals of the battery is about 12V. NO Charge/check the rectifier and its charging circuits;
replace the battery
2 Open the key switch. Next step
3 Check with multimeter to see if the voltage between the YES Next step
black power wire (which is behind the key switch) and the NO Repair or replace the cable
vehicle green ground wire is about 12V.
4 Check with multimeter to see if the voltage between the YES Replace the ECU
black power wire of ECU No.6 stitch and the vehicle NO Repair or replace the cable
green ground wire is about 12V.

Second: Maintenance according to engine failure form

Before diagnose according to the engine failure form please do the initial checks
1. Make sure that the ECU and fault indicating light is ok.
2. Make sure that there’s no fault record by checking with fault diagnosis tester or diagnostic light.
3. Check the idle speed data of electronic control system when the engine is heat and make sure the data is in the normal range.
4. Make sure that the fault do exist and search it to find the exact position.
Then check the appearance:
1. Check the joint place between cable and ground to see if it is clean and tight.
2. Check the air pipes to see if it is broken, twisted or wrong connected.
3. Check the pipe for clogging.
4. Check the connection of throttle body and air inlet pipe for proper sealing.
5. Check the high voltage wire of ignition coil for breakage and aging.
6. Check the connection of the wires for proper position. Check the joints to see if it is loose or with poor contact.

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 Description Reason Remedy
Check the battery, fuse, fuel pump relay, cable.
The system lacks power or the fuel pump plug has no power
Replace ECU if all above is ok. Then check them again
Fuel pump fails to work
Fuel pump is damaged Replace the fuel pump
Fuel pump plug has power
The voltage is too low Check the battery, relay and circuit
Fuel pump wire is inversely connected Exchange the connection
The battery voltage is too low Charge or replace the battery
No fuel pressure Fuel tank lacks power Add fuel, no less than 2.5L
Engine is hard to start, engine stops automatically

Fuel passage is clogged heavily Check the fuel coarse cleaner and fine filter
Failure of fuel pressure adjuster Replace fuel pressure adjuster
Leakage of fuel passage Replace or repair the loose fuel pipe clip or broken fuel pipe
Insufficient fuel Clogging of fuel passage Check the fuel coarse cleaner and fine filter
pressure Failure of fuel pump or fuel pressure adjuster Replace fuel pump or fuel pressure adjuster
Insufficient voltage Check the battery, rectifier and magneto to see is it is charged
Spark plug is damp or choked Remove and clean the spark plug. Idle the engine for a few times
Fuel pump
Electric leakage of spark plug insulation parts Replace the spark plug
is normal
Spark plug is not tightened Tighten
Ignition
Too little clearance of spark plug electrodes Adjust it to the standard value
voltage is
Poor contact or electric leakage of cavity cap Adjust or replace
normal
Fuel pressure is Check the cable joint, throttle position sensor mounting and
Failure of the circuit, poor contact of plug-in
normal circuit connection or plug-in
Engine temperature sensor is damaged Replace
Failure of the engine Check the engine valve, piston ring and mounting.
No ignition Poor contact of ignition circuit Check the joint and restore
voltage or Too much clearance of magneto exciter coil Adjust the exciter coil clearance
ignition off Ignition coil is damaged Replace

4-17
 Electric leakage of ignition coil output Replace the waterproof rubber cover and ignition coil
Poor contact of ECU or cable plug-in Check and connect it well
Clog of fuel injector Replace

Poor contact of circuit Check

The rectifier fails to charge Check or replace
Insufficient generated energy of magneto Check it for short circuit
Insufficient system voltage
The battery is too old and fails to store power Maintenance or replace
Electricity consumption is too large, battery
Avoid long time low speed driving
losses too much power

Third: Safety matters when maintenance of system：

1. Disassembly requirements of ECU：

1）Remove the ECU before weldment.
2）The key switch should be set to off position to avoid damage when disassemble the ECU.
3）The power line should not be remove from the battery when engine or electric system is working.
4）The engine cannot be started by large current of battery charger.
5）Ambient temperature around ECU should not surpass 80℃.
6）Make sure the wire connection is right while voltage and grounding measurement of EFI system.
2. Fuel circuit system:
Disassembly of fuel pump: before operation, please drain out the fuel in the tank. And place the gasoline absorption equipment next to the fuel pump to absorb the
leaked gasoline and avoid direct contact between skin and gasoline.
3. Cleanliness requirements:
Please comply with the following rules before operation to fuel supply system and EFI system.
1）Before loosen the connection position, clean the place and all around thoroughly.

4-18
2）Put a cleaning rag on the connection position to avoid fuel splash.
3）The removed components should be put in clean position and be covered well, but do not use the cloth which drops fiber.
4）If the opened components will not be repaired immediately, it should be covered or sealed carefully.
5）Only the clean components can be installed.
6）Do not damage the O-ring when install the fuel injector. A few lubricating oil is allowed to be coated on the O-ring for the convenience of assembly.

4-19
 4.3 IGNITION SYSTEM
●Ignition system consists of:
Magneto with exciter coil: is of flying wheel convex plate with outer trigger type.
ECU: with other EFI system components, please refer to 4.2 EFI system
Ignition coil: transform low voltage from the igniter into high voltage. Inductive energy storage type
Spark plug: please refer to Motorcycle Owner’s Manual for the spark plug type and contact clearance.
● Removal, Installation and Maintenance of Ignition System
Turn the key from to .to open the ignition switch. Turn the stop switch to to check the ignition system.

STOP SWITCH

IGNITION SWITCH

Remove the spark plug cap. Connect the multimeter (Ω×1k) to the cap. Check it for specified resistance.
Spark plug cap resistance: 5kΩ±0.5 kΩ

Please refer to Motorcycle Owner’s Manual for the spark plug

type and contact clearance

SPARK PLUG CAP

4-20
Check the couplers of magneto exciter coil to main cable for continuity. Replace the parts if necessary
The Blue/White line and Green line is exciter coil. Repair or
replace it if necessary.

MAIN CABLE TO

MAGNETO EXCITER

COIL COUPLER

EXCITER COIL

Extract the coupler between main cable and ECU. Check the plug and replace it if necessary
● Note: Don’t charged inserted ECU controller.

MAIN CABLE TO ECU COUPLER

For other checking, please refer to 4.2 EFI System.

4-21
● Trouble shooting to ignition system (For other checking, please refer to 4.2 EFI System)

Description Damage From Trouble Symptom Remedy

Power of Ignition Broken circuit or poor connection No spark or weak spark Repair

Engine is hard or fails to start. Engine

Short circuit Replace the exciter coil
Exciter Coil lacks power. Unstable idle speed.
Broken circuit (i.e.: resistance is ∞) Engine fails to start. Replace the exciter coil

Ignition Switch/Engine Short circuit Engine stop switch is out of work Replace the faulty switch
Stop Switch
Broken circuit Engine fails to start. Replace the faulty switch
Ignition Controller Damaged Engine fails to start. Replace the controller
Engine is hard to start. Engine lacks
Short circuit Replace the ignition coil
power. Unstable idle speed.
Broken circuit (i.e.: resistance is ∞) Engine fails to start. Replace the ignition coil
Ignition Coil
Insulator burn-in Engine is hard to start. Engine lacks Replace the ignition coil
power. Unstable idle speed. Leakage of
electricity
Carbon deposit, leakage of electricity, Clean the carbon deposit. Properly dilute the
insulator is broken mixture in the carburetor. And then check for
burning engine oil. Or replace spark plug with
the same model.
Engine is hard to start. Engine lacks
Spark plug Electrode wear Adjust the spark plug gap or replace spark
power. Unstable idle speed.
plug with the same model.
Electrode erosion Properly dilute the mixture in the carburetor.
And then check for burning engine oil. Or
replace spark plug with the same model.

4-22
 4.3 SIGNAL SYSTEM, METER, RADIATOR FAN AND WATER TEMPERATURE INDICATOR
Signal system consists of:
Left handlebar switch, horn, winker, LED indicator, flasher relay, LED front position light (included in the headlight), LED taillight (LED brake light, LED rear
position light), front brake switch, rear brake switch, fuel sensor, meter, speed sensor, water temperature sensor, fan, ECU, EFI main relay and so on.
● Removal, Installation and Maintenance of Signal System
Turn the key from to .to open the ignition switch. Turn the stop switch to to check the signal system.

LEFT HANDLE BAR SWITCH

STOP SWITCH

LIGHTING SWITCH

TURN SIGNAL SWITCH

HORN SWITCH
IGNITION SWITCH

LEFT HANDLE BAR SWITCH

Remove the coupler of flasher relay to main cable. Check it
for short circuit, broken circuit or poor contact. Replace it if
necessary.

COUPLER OF OVERTAKING

FLASHER RELAY SWITCH

TO MAIN CABLE

4-23
Remove the coupler of handle bar switch, winker, and meter to main cable or remove COUPLER OF TAILLIGHT, REAR
and open the interior of handle bar switch. Check it for short circuit, broken circuit or
WINKER TO MAIN CABLE
poor contact. Replace it if necessary

TAILLIGHT

COUPLER OF LEFT HANDLE BAR COUPLER OF RIGHT HANDLE

SW., FRONT LEFT WINKER, BAR SW., FRONT RIGHT WINKER,
METER TO MAIN CABLE METER TO MAIN CABLE

Disassemble the left and right

side cover, back panel. Check
MOUNTING SCREW OF LEFT INTERAL PICTURE OF LEFT or replace the rear brake light
HANDLE BAR SW. HANDLER BAR SW.
and rear position light.

COUPLER OF LED FRONT POSITION

LIGHT AND LED HEADLIGHT

4-24
 Check the coupler of front brake switch and rear brake switch to main
cable for continuity, and also front or rear brake switch. Repair or Check the coupler of winker to main cable for continuity. Repair or replace
replace them if necessary. them if there’s short circuit, broken circuit or poor contact. If the bulb has
broken, disassemble the winker and replace the bulb with a new same-type one.

COUPLER OF MAIN CABLE TO

FRONT BRAKE SW. MOUNTING SCREW OF

WINKER HOUSING

COUPLER OF MAIN CABLE TO

REAR BRAKE SW.

TURN SIGNAL BULB

REAR BRAKE SW.

Checking method of front and rear winker are the same.

4-25
 COUPLER OF MAIN CABLE TO
Check the coupler of horn to main cable for continuity. Replace the faulty part. Turning
GEARSHIFT SW.
the adjusting screw to adjust the horn if the horn sound is weak or without sound.

COUPLER OF HORN TO

MAIN CABLE

ADJUSTING SCREW

OF HORN SOUND
COUPLER OF MAIN CABLE TO METER

Check such couplers as connect to main cable, meter, gearshift COUPLER OF METER TO SPEED

switch, fuel sensor, front position light, taillight etc. for SENSOR

continuity. Check the coupler of speed sensor to meter for

continuity. If there’s short circuit, broken circuit, or poor
contact, repair or replace the faulty parts with a new same-type
one.
Indication for float of fuel sensor in two limit positions FUEL SENSOR（under the
(connected to LF200-10P meter to test): F point (highest fuel fuel tank）
level), fuel gauge LCD indicates 5; E point (lowest fuel level),
fuel gauge LCD indicates 1; if the float changes between F to
E point, fuel gauge LCD indicates 1 to 5. When the gear COUPLER OF MAIN CABLE TO FUEL SENSOR

switch is set to a gear position, and the gear line is connected

to negative of battery and housing of engine, the gear indicator
will glow at present.
When operating the left/right turn signal switch, the left/right
turn signal indicator and left/right winker will be light. The
4-26
high beam light and meter light will be light when the
overtaking switch is pressed.
 ODOMETER 时钟 SPEEDOMETER
Function description of LCD
1. Vehicle speed: maximum 199;
GEAR INDICATOR
2. Total accumulative mileage ODO: 6 numbers, maximum 99999.9;
3. Temporary accumulative mileage TRIP: 6 numbers, maximum 99999.9;
4. Gear indicating: 1~6 gears
5. Fuel gauge: 5 level, the lowest level flashes when fuel starvation
LCD
6. Clock: 12 hours type (morning: AM; afternoon: PM)
HIGH BEAM

INDICATOR FUEL GAUGE TACHOMETER OVERSPEED ALARM INDICATOR Function description of buttons
1. Right button:
a. Short press the right button (less than 1 second) to change the LED
backlight (blue or orange).
b. Long press the right button (more than 3 seconds) to set the clock.
When the “hour” place flashes, short press the right button (less than 1 second)
to set the hour. If there’s no operation within 5 seconds, clock setting mode
exit. If long press the right button (more than 3 seconds), it will enter minute
setting mode. Minute setting is the same with hour setting.
2. Left button:
a. Short press the left button (less than 1 second) to switch ODO and
TRIP mode.
b. If it is in ODO mode, long press the left button (more than 3 seconds)
to switch metric unit and British unit.
c. If it is in TRIP mode, long press the left button (more than 3 seconds)
to reset subtotal mileage.
EFI TROUBLE LIGHT WATER TEMPERATURE ALARM LIGHT RIGHT BUTTON 3. Requirements to left & right buttons
Operate the buttons flexibly. There’s should be reliable response for each
RIGHT TURN SIGNAL LIGHT
LEFT TURN SIGNAL INDICATOR LEFT BUTTON
FUEL WARNING INDICATOR operation.
NEUTRAL INDICATOR

The odometer is with electronic type speed sensor. Output signal of speed sensor: square-wave pulse. When the frequency if 18.5Hz, the speedometer indicates
65±1km/h or 39.8±1.6mph.
Left & right turn signal indicator and neutral indicator are green; high beam indicator is blue; water temperature alarm light and overspeed alarm indicator are
red; fuel warning indicator is yellow. LCD backlight is sky blue or orange. All the indicators and LCD backlight are LED lighting.
Checking of radiator fan, water temperature indicating system: check the function of fan, water temperature alarm indicator, water temperature sensor, and ECU.

4-27
If there’s short circuit, broken circuit or poor contact of couplers, replace them with the same-type one.
Resistance of water temperature sensor: the resistance is 2.5±0.1kΩ when it is 20℃
Check the water temperature alarm indicator to see if it lights after it is connected to ECU (it will light when green/blue wire connected to green wire)
ECU receives the signal and it controls the fan through EFI main relay (the fan runs when ECU is connected with brown and green wire of EFI main relay). If
the water temperature on the outlet of cylinder head is above 92℃, the fan runs; if it is below 89℃, the fan stops to run.

FAN COUPLER OF FAN TO MAIN CABLE

Remove the front axle to check or replace the speed sensor

SPEED SENSOR

METER CABLE
Speed sensor is with electronic type and meter is full-electronic meter.
Speedometer and odometer indicate vehicle current speed and accumulative
mileage separately. They are driven by front wheel. Check the speed sensor. COUPLER OF MAIN
Replace it if necessary. CABLE TO WATER
TEMPERATURE SENSOR
If there’s fault about speedometer, odometer, tachometer or meter
indicating, it needs to disassemble the meter to check. If the circuit is normal
WATER TEMPERATURE
(no short circuit, broken circuit, poor contact), it needs to replace the meter.
SENSOR

4-28
 ● Troubleshooting to Signal System
Description Damage Form Trouble Symptom Remedy
Winker Damaged The winker is out of work Replace the bulb with the same type
Indicating lights Damage of meter interior LED indicating lights are out of work Replace the meter
Poor connection of inner circuit or wire is broken
Turn signal switch The winker is out of work Repair or replace the turn signal switch
or damaged
Flasher relay Damage of interior The winker is out of work or does not twinkle Replace the flasher relay
Front/rear brake switch Switch return is abnormal; the parts are damaged Brake light keeps on or does not light Replace the brake switch
Taillight/brake light Damage of interior LED taillight or LED brake light are out of work Replace the taillight
The LED front position light is out of work or its light
Front position light Damage of interior Replace the headlight with the same type
intensity is abnormal
Poor connection of inner circuit or wire is broken The horn is out of work or has abnormal
Horn switch Repair or replace the horn switch
or damaged sound
The horn is out of work or has abnormal
Horn Inner wire is broken or damaged Replace the horn
sound
Gear switch Poor connection of gear switch when gear shifting The gear indicator is out of work Replace the gear switch
Gear indicator Damage of meter interior The gear indicator is out of work Replace the meter
Fuel sensor Damage of interior Fuel gauge fails to indicate correctly Replace fuel sensor
Water temperature alarm LED water temperature alarm light keeps on or does
Damage of meter interior Replace the meter
light not light
EFI main relay Damage of interior The fan fails to run Replace the EFI main relay with the same type
ECU Damage of interior The fan fails to run Replace the ECU with the same type
Water temperature alarm light keeps on or does not Replace the water temperature sensor with the same
Water temperature sensor Damage of interior
light type
Fan Damage of interior The fan fails to run Replace the fan with the same type
Speed sensor Damage of interior Speedometer or odometer fail to indicate correctly Replace the speed sensor with the same type
Cable is damaged, broken or short circuit, or poor Lighting and signal indicating system fails to work
Meter cable Replace the meter cable
contact correctly

4-29
 4.5 LIGHTING SYSTEM
Lighting system consists of:
Right handle bar switch, left handlebar switch, headlight assembly (high beam and low beam, front position light), license plate lamp and so on.
● Removal, Installation and Maintenance of Lighting System
Turn the key from to to open the ignition switch. Check the signal system.

RIGHT HANDLE BAR SW.

LIGHTING SW.

IGNITION SW.

DIMMER SW.

LEFT HANDLE BAR SW.

MOUNTING SCREW OF

LEFT HANDLE BAR SW.

INNTERIOR VIEW
COUPLER OF LED FRONT
OF LEFT HANDLE POSITION LIGHT TO LED
BAR SW. HEADLIGHT

4-30
 COUPLER OF LICENSE

PLATE LIGHT TO MAIN

MOUNTING SCREW OF CABLE

RIGHT HANDLE BAR SW.

MOUNTING SCREW OF LICENSE PLATE

LIGHT HOUSING
INNTERIOR VIEW
OF RIGHT
HANDLE BAR SW.

COUPLER OF IGNITION SW.

COUPLER OF MAIN CABLE TO

IGNITION S.

COUPLER OF LEFT HANDLE BAR COUPLER OF RIGHT HANDLE

SW., HEADLIGHT TO MAIN CABLE BAR SW. TO MAIN CABLE BULB OF LICENSE PLATE

4-31
 Check the couplers of left & right handle bar switch, license plate light, and ignition switch to main cable. Check the couplers of left & right handle
bar switch to headlight. Replace the coupler if there’s short circuit, broken circuit or poor contact.
If necessary, disassemble the license plate light to check the bulb. Replace it with a same type one if necessary. If the interior of headlight has damaged
and light beam is improper, it needs to remove the covering parts and replace headlight assembly.
If necessary, disassemble the left & right handle bar switch. Check it for short circuit, broken circuit or poor contact. Replace it if necessary.
Check the interior of main cable or ignition switch. Check them for short circuit, broken circuit or poor contact. Replace them if necessary.
Check the coupler of ignition switch to main cable for short circuit, broken circuit or poor contact. Replace them if necessary.

COUPLER OF MAIN CABLE

TO IGNITION SW.

● Troubleshooting to Lighting System

Description Damage Form Trouble Symptom Remedy
Adjusting screw of light length is
Light beam is improper (too near or too far) Adjust the screw and fasten
Headlight loose

Damage of internal circuit or parts LED light beam fails to light Replace the headlight

License plate light Bulb burnt out Bulb fails to light Replace the bulb with the same type

Lighting Switch or Poor contacts or circuits

Bulb fails to light or light improperly Repair or replace the switch
Dimmer Switch damaged

4-32
 4.6 ELECTRIC STARTING SYSTEM
Electric starting system consists of:
Starting motor, starting relay, stop switch, electric starter button (on the right handle bar switch), clutch switch, gear switch, diode, grounded cable, battery, fuse etc.
●Removal, Installation and Maintenance of Electric Starting System
Turn the key from to to open the ignition switch. Turn the stop switch to to check the electric starting system.

IGNITION SW.

STOP SW.

ELECTRIC STARTER

BUTTON

COUPLER OF MAIN CABLE TO

IGNITION SW.

INTERIOR VIEW OF RIGHT

HANDLE BAR SW.

GOUNDED CABLE TO ENGINE

HOUSING

4-33
 COUPLER OF STARTING RELAY

COIL TO MAIN CABLE DIODE

COUPLER OF STARTING RELAY

STARTING
TO BATTERY POSITIVE WIRE OF
RELAY
MAIN RELAY

COUPLER OF STARTING MOTOR

PSITIVE WIRE TO STARTING
RELAY

POSITIVE WIRE OF
STARTING MOTOR
COUPLER OF MAIN

CABLE TO GEAR SW.

STARTING
MOTOR

CLUTCH SW. AND COUPLER

Check parts such as coupler of ignition switch, stop switch, starter button, clutch switch, gear switch, diode, starting relay, and engine housing (grounded cable) to
main cable for continuity. Check the related parts for short circuit, broken circuit or poor contact. Repair or replace the part if necessary.
There are two ways for electric starting: when engine is in neutral, it can be electric started; when engine is not in neutral, it can be electric started by grasping
the clutch lever (The clutch switch is on).
● Troubleshooting to electric starting system

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Description Damage Form Trouble Symptom Remedy
Starting Relay Short circuit or broken circuit of internal coil Motorcycle fails to electric start Replace the relay
Damaged of interior Motorcycle fails to electric start Replace the relay
All switches Damaged or poor connection inside Motorcycle fails to start Replace the damaged switch
Diode is damaged or broken circuit Motorcycle fails to start Replace the diode
Diode
Diode is damaged or short circuit Neutral indicator lights when clench the clutch lever Replace the diode
Check the battery for proper function.
Battery No voltage or voltage is too low Motorcycle fails to start
Repair or replace the battery

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 4.7 BATTERY AND FUSE

FUSE CONNECTING WIRE

BETWEEN MAIN CABLE
AND BATTERY NEGATIVE

CONNECTING WIRE
BETWEEN MAIN CABLE
BATTERY
AND BATTERY POSITIVE

Measure the voltage of battery, if it is below 12V, charge the battery.

Check the fuse; replace it with a new one if necessary. Specially pay attention to specification (20A) of fuse when replace it. Never use other material such as
aluminium, iron or copper wire instead. Otherwise the circuit may be burnt.
Battery (12V9Ah): free of maintenance
Specification of fuse: 20V. There is a fuse in the fuse box as a substitute.

Battery Maintenance:
（1）Battery 12V9Ah: is of maintenance-free type. The electrolyte has been added in delivery condition at the factory.
Compared with the traditional one, the maintenance-free battery has many good properties such as free of adding
distilled water, no corrosion of the terminal, less amount of self-discharge. The battery should be charged trimonthly if it
is not used for a long time, because it will self-discharge and cause insufficient capacity. The battery capacity will also
decline after using for 2~3 years. The voltage can be recovered by charging in this case.
（2）There’s no need to check or repair the battery because it is of maintenance-free type. But remember never remove
the sealed electrolyte cover. During long-term storage of vehicle which is not in use, please remove the battery and store
the charged battery in a cool, well-ventilated place.
（3）Clean of battery terminals: Turn off the ignition switch, remove the left side cover; disconnect the negative lead and
positive lead from the battery. Clean the battery terminals with wire brush as shown. This done, coats the terminals with
a thin layer of grease or petrolatum. Connect the battery cables in reverse order of removal. Connect the battery cables in
reverse order of removal.

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Attention: If the battery is to be removed, disconnect the negative lead, then the positive lead.
Connection should be done in reverse order of removal.

Replacement of Fuse:
（1）Before checking and replace the fuse, turn the ignition switch to “ ” so as to prevent an accidental short circuit.
（2）Remove the left side cover. The fuse is in the fuse box. Open the fuse box to replace the fuse and check it for tightness.
（3）If the fuse burns out repeatedly, there is probably a overload circuit or short circuit . The problem must be located, and remedy it.
（4）Replace a fuse of the same rating. Specification of fuse: 20A . Never replace with the different rated current fuse. Never use wire to take the place of fuse.
WARNING：Never use other material such as aluminium, iron or copper wire instead. Never connect the circuit with out the fuse. Otherwise the circuit
may be burnt.
（5）Reinstall the parts in the reverse order of removal. Check all wire clamps are secure.

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 4.8 ELECTRICAL HORN
Checking of electrical horn:
Turn the main switch to“ ”. The horn should sound when pressing the horn button.
Check the coupler of horn to main cable for continuity. Check the horn button for short or broken circuit and poor connection. If any trouble is detected, remedy it or
replace the faulty part. If the horn fails to sound or sound weakly, turn the adjusting screw of horn sound until meeting the requirements. Replace the damaged horn
with a new one of the same specification.

COUPLER OF HORN

TO MAIN CABLE

ADJUSTING SCREW OF

HORN SOUND

No sound of horn is one of commonly troubles. It can be divided into two kinds as follow: a electric circuit and a horn inside.
1）Check the electric circuit
When the horn is out of work, first check the fuse, then check the circuits of horn. If above-mentioned parts are good, it means that there is probably a problem on
the horn.
2）Horn
When examining the horn, the following faults are likely to be detected: erosion appeared on the connectors, damage to coil, diaphragm broken, etc. Among which,
erosion appeared on connectors is the most common. Erosion forming on the surfaces of connectors has a process of development as follows: horn sounds later when
pushing the button, no sound, small sound, discontinuous sound in due succession. In this case, erosion appeared on the connectors is considered as a trouble cause.

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 CHAPTER 5 SERVICE
5.1 ROUTINE MAINTENANCE AND ADJUSTMENT
5.1.1 Maintenance of Drive Chain: 5.1.3. Maintenance of Fuse System
For maximum service life, the chain should be cleaned, and adjusted before 5.1.3.1 Fuel system schematic of National stage Ⅲ
each outing. Lubricate the chain if it seems to be dry. Slack should be 15-25mm,
support the motorcycle with center stand, and check slack in the lower drive
chain run midway between the sprockets.

5.1.2 Adjustment
AIR
Loose the nut of rear axle and locknut of chain adjuster, turn both adjusting EXHAUST MUFFLER
FILTER
CARBON
ENGINE
SECONDARY OIL-GAS FUEL TANK
CANISTER GULP VALVE SEPARATOR
bolts until the chain slack meets the standard, and make sure left and right 1. Turn off the fuel cock; remove the fuel pipe and empty fuel inside the fuel
adjusters align with the same index marks. After checking, tighten up the rear tank.
axle nut. Tightening torque of rear axle nut: 70～90N·m 2. Unscrew the bolt of seat, and remove the seat.
3. Remove the key fuel tank. Check the gasket for deformation and wear.
Replace it if necessary.
4. Remove the fuel tank, check the fuel tank inside. Clean it if necessary.
5. Remove the fuel cap.
6. Remove the fuel pump; check the filter tube and strainer. Replace them if
necessary.
7. Check the rubber pipes of evaporative system for twist, damage, and aging.
Replace them if necessary.

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5.1.3.2 Troubleshooting to fuel system
Trouble Symptom
Description Damage From Trouble Symptom of Motorcycle Remedy Remarks
of Parts
Cracks on the tank due to Fuel leakage of Repair or replace
erosion fuel tank
Fuel Tank
Vent in the fuel cap is No fuel supply Engine fails to start Clean the vent Vent in the fuel cap is
clogged clogged (National stage Ⅲ)
Engine is hard or fails to start. Engine
Strainer is clogged No fuel supply Clean the fuel cock
lacks power. Idle speed is unstable
Fuel cock
Fuel cock is damaged or
No fuel supply Engine fails to start Replace the fuel cock
clogged
5.1.4 Clean and Installation of Fuel Filter:
Fuel filter is the strainer of fuel cock. Open the seat and remove it. Unscrew the mounting screw of left side cover, and remove the left side cover. Unscrew the
mounting screw of fuel cock lever and remove it. Unscrew the fixing screw of fuel cock to remove the strainer. Clean the strainer with gasoline, and then assemble
the strainer and fuel cock in the reverse order of removal.

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5.1.5 Check of Fasteners
Lock nut of steering stem: 60-90 N·m;
Nut of front axle: 60-80N·m; Nut of rear axle:70-90 N·m;
Nut of engine suspension axle: 24-30N·m;
Nut of rear fork shaft: 70-90N·m
Tighten the fasteners such as ones of upper connecting plate, front/rear wheel,
engine etc. to specified torque(s) by means of torque wrench, and check.

Nut of rear axle

Lock nut of steering stem

Nut of engine suspension axle

Nut of rear fork shaft

Nut of front axle

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 5.2 PRE-RIDE INSPECTION
Check the following before each ride:
1. Engine oil level——Add engine oil if necessary. check for leaks.
2. Fuel level——Refuel if necessary. Check for leaks.
3. Front and rear brakes——Check operation, and adjust free play if necessary.
4. Tyres——Check condition and pressure
5. Battery electrolyte——Check that the electrolyte level is suitable. (Between the upper and lower limit)
6. Throttle——Check for smooth opening and full closing in all steering positions. Adjust or replace it if necessary.
7. Lights and horn——Check that headlights, tail/stop light, winkers, parting light, indicators and horn function properly.
8. Drive chain——Check condition and slack. Adjust and lubricate if necessary.
9. Front and rear axles, shock absorbers, engine mounting and all fasteners——Check that the parts are mounted securely.
10. Steering system——Check for its smoothness and reliability.

5.3 GENERAL MAINTENANCE

5.3.1 Tool Kit

1. Screw driver grip 1 pc.

2. Double-end screw driver 1 pc.
3. Spark plug wrench, 16#×18＃ 1 pc.
4. Open-ended spanner, 8mm×10mm 1 pc.
5. Open-ended spanner, 13mm×15mm 1 pc.
6. Tool bag 1 pc.

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5.3.2 Maintenance Schedule
REGULAR SERVICE Item ODOMETER READING, km（Note ②）
ITEM Period 1.000km 4.000 km 8.000 km 12.000 km Note
· Fuel line system Ⅰ Ⅰ Ⅰ
· Fuel filter C C C C
· Throttle operation Ⅰ Ⅰ Ⅰ Ⅰ
· Carburetor choke Ⅰ Ⅰ Ⅰ
Air cleaner element Note ① C C C
Spark plug Ⅰ Ⅰ Ⅰ Ⅰ
· Valve gap Ⅰ Ⅰ Ⅰ Ⅰ
Engine oil Yearly R Every 2,000kmR
Strainer of lubricant Yearly R C
· Tension degree of cam chain A A A A
· Engine idle speed Ⅰ Ⅰ Ⅰ Ⅰ
Drive chain Ⅰ, L Ⅰ, L Ⅰ, L Ⅰ, L
Battery Monthly Ⅰ Ⅰ Ⅰ Ⅰ
Brake shoes/pad wear Ⅰ Ⅰ Ⅰ
Brake system Ⅰ Ⅰ Ⅰ Ⅰ
· Stop light switch Ⅰ Ⅰ Ⅰ Ⅰ
· Headlight adjustment Ⅰ Ⅰ Ⅰ Ⅰ
Clutch Ⅰ Ⅰ Ⅰ Ⅰ
Side stand Ⅰ Ⅰ Ⅰ
· Suspension Ⅰ Ⅰ Ⅰ Ⅰ
· Nuts, bolts, fasteners Ⅰ Ⅰ Ⅰ Ⅰ
·· Wheels/spokes Ⅰ Ⅰ Ⅰ Ⅰ
·· Turn signal, steering and bearing Ⅰ Ⅰ

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Maintenance work should be performed in light of Maintenance Schedule.
Letters in the table indicate as follows:
I：Inspect and clean, adjust, lubricate or replace if necessary；
C：Clean；
R：Replace；
A：Adjust；
L：Lubricate
NOTES: ① Clean more frequently when riding in unusual wet or dusty areas;
② At higher odometer readings, still follow the frequency intervals established in this manual.

5.4 STORAGE
If you won’t be riding for an extended period, take measures as following before storing the motorcycle.
1. Empty fuel inside the fuel tank, carburetor and other pipes.
2. Unscrew the spark plug, and pour a bit of clean engine oil into the cylinder. Turn off the ignition switch, and crank the engine several revolutions to scatter evenly
the oil inside the cylinder.
3. Remove the drive chain, clean and oil it.
4. Lubricate all of the controlling cables.
5. Cover the motorcycle well (Do not cover with plastic cloth or cloth with coating). Store the motorcycle in a place which is with low temperature, dry and low daily
temperature difference. Please do not store the motorcycle in the place which is with direct sunlight.
6. Seal the muffler outlet with a plastic bag to prevent moisture from entering.
7. Coat all surfaces of bare metal with a thin layer of rust-resisting oil if the motorcycle is to be exposed to sea air or salt water.
8. Remove the battery and store it in a dry, cool and well-ventilated place. Charge the battery once every 30-day.
5.5 UNPACKING
Place the packed motorcycle on a level ground. Unpack the packing case with a special tool to prevent scratching of the body surfaces. This done, check to see that
all parts of the motorcycle are intact and good, and check the allotted tools for completeness.

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