Lifan LF200-10P Manual
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Lifan LF200-10P Manual

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1.1 VEHICLE INTRODUCTION-------------------------------------------------------------------------------------------------------1-1
1.2
-----------------------------------------------------------------------------------------------------------------------1-2
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
CONTENTS

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Summary of Contents for Lifan LF200-10P

  • Page 1: Table Of Contents

    CONTENTS CHAPTER 1 GENERAL 1.1 VEHICLE INTRODUCTION-------------------------------------------------------------------------------------------------------1-1 -----------------------------------------------------------------------------------------------------------------------1-2 SPECIFICATIONS 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...
  • Page 2 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...
  • Page 3 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...
  • Page 4 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.

  • Page 5: 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...

  • Page 6: Specifications

    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)
  • Page 7 Turning circle dia. 4860mm Clutch Wet, multi-plate type Transmission 6-speed, constant mesh Primary reduction 3.333 Final reduction 2.800 2.909 Drive Train 1.867 Gear ratio 1.316 1.000 0.833 Type 08MC Drive chain Link No. Front Disk Brake Rear Disk Ignition Inductive energy storage Static ignition timing (°CA) 40°...
  • Page 8 High beam indicator LED/8mA urn signal indicator LED/8mA Meter light LED/8mA Fuel type RQ-93 Capacity Fuel tank Reserve 2.8L Fuel/Oil Brand 15W/40-SF Engine oil Capacity Brand HQ-10 Damping oil Capacity 320ml...

  • Page 9: Chapter 2 Engine

    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.
  • Page 10 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）...
  • Page 11 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.
  • Page 12 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 Service limit: ＞Φ 5.54mm valve if it is beyond the limit. Service limit:＞1.6mm guide.
  • Page 13 17) Unscrew and remove the bolt of thermostat and remove the thermostat. (NOTE: Bolt specification: M6×16 Tightening torque of bolt 8～12N.m）...
  • Page 14 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 Engine fails or is hard to start Repair threaded hole or replace the cylinder head plug is damaged cylinder head...
  • Page 15 Improper 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.

  • Page 16: Cylinder Block

    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.
  • Page 17 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 Service limit: ＞Φ 65.55mm the crankcase） the cylinder. CIRCLIP 6）Pull out the piston pin and check it for wear. Replace it if it is out of the Service limit: ＜Φ...
  • Page 18 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 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...

  • Page 19: Valve Train

    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.
  • Page 20 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 Service limit: ＜Φ 4.95mm if necessary. valve. 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.
  • Page 21 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.
  • Page 22 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”...
  • Page 23 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...

  • Page 24: Transmission

    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.
  • Page 25 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.
  • Page 26 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.
  • Page 27 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 Service limit: ＜35mm is out of the limit. out of the limit. Service limit: ＜1.4mm 2-19...
  • Page 28 2.4.2 Troubleshooting to clutch Description Damage Form Trouble Symptom of Component Trouble Symptom of Motorcycle Remedy Hub grooves are worn into saw Trim the grooves with saw Friction discs fail to remove freely Clutch slipping. Out of function. Clutch outer teeth-shaped or replace the clutch outer in the hub grooves.
  • Page 29 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.
  • Page 30 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.
  • Page 31 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.
  • Page 32 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.
  • Page 33 19）Remove the bush and washer of starting mid-gears. Check them for wear. 21）Remove the bush of countershaft 1 gear and washer I, then check them for Replace them if necessary. wear. Replace the worn part. 20）Remove the countershaft 1 gear, and then check it for wear. Replace the 22）Remove the countershaft 3 gear, and then check it for wear.
  • Page 34 23）Remove the washer II from the countershaft, and check it for wear. Replace 25）Remove the countershaft 5 gear, 4 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 2 gear, and then check it for wear.
  • Page 35 27）Remove the 2 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 5 gear from the mainshaft, and check it for wear. Replace the 30）Remove the 4th gear from the mainshaft, then check it for wear.
  • Page 36 31）Remove the starting driven gear set and washer, then check them for wear. Replace the worn part. 2-28...
  • Page 37 Troubleshooting to transmission 2.4.4 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 worn into arc Gear...

  • Page 38: Crankcase

    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. Check the clutch rod for wear.
  • Page 39 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.
  • Page 40 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...
  • Page 41 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...
  • Page 42 17）Check the water pump gear and O-ring for wear, replace them if necessary. O-RING 2-34...
  • Page 43 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 leakage between RH/LH Repair or replace damaged crankcases Gas leakage between cylinder head Engine fails or is hard to start.

  • Page 44: Crank Mechanism

    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 wear. Replace the worn-out gear with a new one. Note: The “O” mark of timing Replace them if necessary drive gear should be aligned with crank woodruff groove.
  • Page 45 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.
  • Page 46 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.
  • Page 47 2.6.2 Troubleshooting to Crankshaft Mechanism Trouble Symptom of Description Damage Form Trouble Symptom of Vehicle Remedy Component Engine overheats Clear away carbon deposit Carbon deposit on the piston top Engine fails or is hard to start. Engine lacks Carbon deposit in the piston ring The piston ring is seized in the power.

  • Page 48: Starters

    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.
  • Page 49 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.
  • Page 50 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 Gear is worn Starting is slipping Starting is slipping Replace the gear with a new one...
  • Page 51 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 cover, replace it if necessary.
  • Page 52 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.
  • Page 53 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.
  • Page 54 13）Check the coils of both rotor and stator of magneto for damage. Replace the damaged part. 2-46...
  • Page 55 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...

  • Page 56: Lubrication System

    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: hexagon socket head, M6×90 (Bolt specification: M6×12...
  • Page 57 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.
  • Page 58 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.
  • Page 59 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.
  • Page 60 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...

  • Page 61: Chapter 3 Chassis

    CHAPTER 3 CHASSIS FRAME BODY 3.1.1 Motorcycle identification The vehicle identification number (VIN) is stamped Maintenance of Frame 3.1.2 into the left of steering stem. Damage Description Trouble Symptom Remedy From Frame Frame deformed Running off-tracking Correct or replace ： broken Deformed or Replace...
  • Page 62 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.
  • Page 63 5) Check the rear fender for damage. Replace it if necessary. 7) Check the pillion footrest for wear. Replace it if necessary. PILLION FOOTREST REAR FENDER 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...
  • Page 64 9) Check the pillion rail for damage. Replace it if necessary. 11) Check the fuel tank for leakage. Replace it if necessary. FUEL TANK PILLION RAIL 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...
  • Page 65 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...

  • Page 66: Suspension System

    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.
  • Page 67 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.
  • Page 68 ●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...

  • Page 69: Front Suspension

    FRONT SUSPENSION  3.3.1 Removal, Installation and Maintenance of Front Shock Absorber 3） ）Unscrew the locknuts of front axle. Remove the front axle and front wheel. 1）Unscrew the bolt of top bridge and steering bar. 2）Unscrew the bolt of bottom bridge. 4）Unscrew the mounting bolt from front fender.
  • Page 70 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.
  • Page 71 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.
  • Page 72 3.3.2 Troubleshooting to Front Shock Absorber Description Damage Form Trouble Symptom Remedy spring non-elastic 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...

  • Page 73: Rear Suspension

    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.
  • Page 74 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 broken too weak or stiff spring...

  • Page 75: Front And Rear Wheels

    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.
  • Page 76 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...
  • Page 77 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）...
  • Page 78 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.
  • Page 79 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.
  • Page 80 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 Oil seal of front axle is worn Too much dirt in the oil seal of front axle Replace the oil seal of front axle Front Wheel Exhaust the air in the front hydraulic brake.

  • Page 81: Intake System And Exhaust System

    3.6 INTAKE SYSTEM AND EXHAUST SYSTEM  3.6.1 3） Remove the element of air filter. Check it for damage. Replace it if necessary. Removal, Installation and Maintenance of Intake System 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.
  • Page 82 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.
  • Page 83 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...
  • Page 84 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 whenever the ex.

  • Page 85: Cooling System

    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.
  • Page 86 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...
  • Page 87 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 much dirt, coolant liquid, no Clean Clogged circulation about radiator coolant liquid, replace it Radiator engine overheats No circulation about Replace Damaged...

  • Page 88: Chapter 4 Electrical Components And Meter

    CHAPTER 4 ELECTRICAL COMPONENTS AND METER ●Configuration of Electrical Components on the Vehicle HEADLIGHT CLUTCH SW. TAILLINGT LEFT HANDLE BAR SW. FLASHER RELAY FR. POSITION LIGHT RR. WINKER FR. WINKER LICENSE PLATE LIGHT STARTING RELAY BATTERY STARTING MOTOR MAGNETO & GEAR WATER TEMPERATURE SPEED SENSOR FUSE...
  • Page 89 DIAGNOSE INTERFACE RESERVED INTERFACE FOR FOR EFI FUEL PUMP & FUEL METER BURGLAR ALARM IGNITION SW. EFI CONTROLLER SENSOR RECTIFIER HANDLEBAR SW., RH RR. BRAKE SW. FR. BRAKE SW. SPARK PLUG IGNITION COIL HORN...
  • Page 90 ●ELECTRIC DIAGRAM...

  • Page 91: Charging System

    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.
  • Page 92 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;...
  • Page 93 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...

  • Page 94: Efi System

    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...
  • Page 95 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 direction (A向) 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.
  • Page 96 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.
  • Page 97 Engine temperature sensor is mounted on the engine cylinder block. It is used to detect engine temperature. 5. Intake air temperature sensor (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.
  • Page 98 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.
  • Page 99 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.
  • Page 100 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.
  • Page 101 2. Troubleshooting: Maintenance steps Steps Result Subsequent steps First: Maintenance according to fault code from the fault light: Open the key switch, run the fuel pump Next step 1）Maintenance of throttle position sensor for 3 seconds by listening (by touching is also ok) Extract the sensor plug on the cable.
  • Page 102 Maintenance steps Steps Result Subsequent steps 3）Maintenance of oxygen sensor Open the key switch, run the fuel pump for 3 Next step seconds by listening (by touching is also ok). Start the engine. Extract the sensor plug on the cable. Check Next step with multimeter to see if the voltage between No.3 and No.4 stitches is 12V.
  • Page 103 5）Test of system voltage 4. Fault code 34----system voltage Maintenance steps Steps Result Subsequent steps Check with multimeter to see if the voltage between Next step positive and negative terminals of the battery is about 12V. Charge/check the rectifier and its charging circuits; replace the battery Open the key switch.
  • Page 104 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...
  • Page 105 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...
  • Page 106 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.

  • Page 107: Ignition System

    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.
  • Page 108 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.
  • Page 109 ● Trouble shooting to ignition system (For other checking, please refer to 4.2 EFI System) Remedy Description Damage From Trouble Symptom 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...

  • Page 110: Signal System, Meter, Radiator Fan And Water Temperature Indicator

    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. ●...
  • Page 111 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...
  • Page 112 Check the coupler of front brake switch and rear brake switch to main Check the coupler of winker to main cable for continuity. Repair or replace cable for continuity, and also front or rear brake switch. Repair or them if there’s short circuit, broken circuit or poor contact. If the bulb has replace them if necessary.
  • Page 113 Indication for float of fuel sensor in two limit positions （under the FUEL SENSOR (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 COUPLER OF MAIN CABLE TO FUEL SENSOR E point, fuel gauge LCD indicates 1 to 5.
  • Page 114 时钟 ODOMETER 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 6.
  • Page 115 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).
  • Page 116 ● 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...

  • Page 117: Lighting System

    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 open the ignition switch.
  • Page 118 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 BULB OF LICENSE PLATE...
  • Page 119 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.

  • Page 120: Electric Starting System

    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 open the ignition switch.
  • Page 121 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 STARTING RELAY POSITIVE WIRE STARTING MOTOR COUPLER OF MAIN CABLE TO GEAR SW. STARTING MOTOR CLUTCH SW.
  • Page 122 Description Damage Form Trouble Symptom Remedy Short circuit or broken circuit of internal coil Motorcycle fails to electric start Replace the relay Starting Relay Damaged of interior Motorcycle fails to electric start Replace the relay Damaged or poor connection inside All switches Motorcycle fails to start Replace the damaged switch...

  • Page 123: Battery And Fuse

    4.7 BATTERY AND FUSE CONNECTING WIRE FUSE 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.
  • Page 124 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. placement of Fuse: （1）Before checking and replace the fuse, turn the ignition switch to “ ”...

  • Page 125: Electrical Horn

    4.8 ELECTRICAL HORN Checking of electrical horn: ”. The horn should sound when pressing the horn button. Turn the main switch to“ 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.

  • Page 126: Chapter 5 Service

    CHAPTER 5 SERVICE ROUTINE MAINTENANCE AND ADJUSTMENT 5.1.1 Maintenance of Drive Chain: 5.1.3. Maintenance of Fuse System 5.1.3.1 Fuel system schematic of National stage Ⅲ For maximum service life, the chain should be cleaned, and adjusted before 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.
  • Page 127 5.1.3.2 roubleshooting 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...
  • Page 128 .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.

  • Page 129: Pre-Ride Inspection

    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.

  • Page 130: Maintenance Schedule

    5.3.2 Maintenance Schedule ODOMETER READING, km（Note ②） REGULAR SERVICE Item ITEM Period 1.000km 4.000 km 8.000 km 12.000 km Note · Ⅰ Ⅰ Ⅰ Fuel line system · Fuel filter · Ⅰ Ⅰ Ⅰ Ⅰ Throttle operation · Ⅰ Ⅰ Ⅰ...

  • Page 131: Storage

    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...

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