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Lifan LF125-26C EU V 2024 Service Manual
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Lifan LF125-26C EU V 2024 Service Manual

Lifan LF125-26C EU V 2024 Service Manual

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Summary of Contents for Lifan LF125-26C EU V 2024

  • Page 2 With both the descriptions and figures/drawings, you may have a comprehensive understanding of the structure as well as service and repair skill. Lifan Technology (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.

  • Page 3: Table Of Contents

    CONTENT 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………………………..…………………………................2-10 2.3 VALVE TRAIN……………………………………………………………..............2-16 2.4 CRANKCASE……………………………………………..................2-26 2.5 TRANSMISSION………………………………………....................2-33 2.6 CRANK MECHANISM ………………………………………………....……...........2-50 2.7 STARTER..…………………………………………………..................2-57 2.8 LUBRICATION SYSTEM……………………………………………................2-64...
  • Page 4 CHAPTER 3 CHASSIS 3.1 FRAME BODY..................................3-1 3.2 SUSPENSION SYSTEM..............................3-6 3.3 FRONT SUSPENSION..............................3-10 3.4 REAR SUSPENSION ..............................3-14 3.5 FRONT AND REAR WHEELS............................3-16 3.6 INTAKE SYSTEM AND EXHAUST SYSTEM......................3-21 CHAPTER 4 ELECTRICAL COMPONENTS AND METER 4.1 CHARGING SYSTEM..............................4-4 4.2 IGNITION SYSTEM................................4-7 4.3 SIGNAL SYSTEM AND METER..........................……4-11 4.4 LIGHTING SYSTEM..............................4-16 4.5 ELECTRIC STARTING SYSTEM..........................4-18...
  • Page 5 4.6 BATTERY AND FUSE..............................4-21 4.7 LIGHTS AND HORN..............................4-23 CHAPTER 5 CONSTRUCTION AND MAINTENANCE OF EFI SYSTEM 5.1 INTRODUCTION OF EFI SYSTEM..........................5-1 5.2 CONFIGURATION AND LAYOUT OF EFI PARTS.......................5-2 5.3 EFI PERFORMANCE AND MALFUNCTION.........................5-4 5.4 MALFUCNTION DIAGNOSIS ............................5-11 5.5 TROUBLESHOOTING ..............................5-14 CHAPTER 6 SERVICE 6.1 ROUTINE MAINTENANCE AND ADJUSTMENT ......................6-1...
  • Page 6 6.5 UNPACKING..................................6-5...

  • Page 7: Chapter 1 General

    The large built-in inner trunk better meets the practical needs of users, further highlighting the beauty and practicality of the whole vehicle with full of charm. The vehicle is equipped with Lifan's self-developed horizontal engine of 1P53FMI with single cylinder, air cooler, 4 stroke, high-performance automatic dual clutch, wet multi-plate clutch, electric/kick start and four-speed transmission, which has greater power and torque than engines of the same displacement.

  • Page 8: Specifications

    1.2 Specifications ITEM SPECIFICATIONS Length× Width× Height 1960mm× 715mm× 1110mm Wheelbase 1245mm Dimension and Ground clearance 130mm Weight Kerb mass 177kg Max. weight capacity 150kg Model 1P53FMI Type Horizontal single cylinder, air-cooled, 4 stroke, auto dual clutch, electric/kick start Bore × stroke 53.5 mm×...
  • Page 9 Clutch Wet, multi-plate type Transmission 4-speed, constant mesh Primary reduction 4.059 Final reduction 2.571 2.833 Drive Train 1.706 Gear ratio 1.238 0.958 Drive chain Model 08MB Link No. Front disc brake Braking system Rear disc brake Ignition Ignition advance angle 0-40°...
  • Page 10 Meter backlight Fuel type RQ-92 Capacity 3.0L Fuel tank Reserve 0.7L Fuel/Oil Engine oil Type SF 15W/40 Capacity 0.9L Type HQ-10 Damping oil Capacity (60± 1)mL...

  • Page 11: Chapter 2 Engine

    CHAPTER 2 ENGINE 2.1 CYLINDER HEAD 2.1.1 Removal, Maintenance and Installation 1) Unscrew the left cover bolt M6 from the cylinder head and remove the cover. 3) Unscrew the timing bolt M5 and timing driven sprocket. Tightening torque: 8~12N· m Tightening torque: 6~10N·...

  • Page 12: Cylinder Block

    2.2 CYLINDER BLOCK 2.2.1 Removal, Maintenance and Installation 1) Remove and check the cylinder head gasket and dowel pin for damage, 3) Check the guide pulley for wear, replace it if necessary. replace them if necessary. GUIDE PULLEY PIN WASHER GASKET GUIDE PULLEY PIN GUIDE PULLEY...
  • Page 13 5) Remove the cylinder block. 7) Remove the piston pin circlip. (Attention! Dot not fall the circlip into the crankcase). PISTON PIN CIRCLIP CYLINDER BLOCK 6) Measure the cylinder wall, replace the cylinder if it exceeds the service limit 8) Pull out the piston pin and check it for wear, replace it if it is out of the (Φ53.6mm).
  • Page 14 9) Remove the piston and set aside after cleaning it with kerosene. PISTON 10) Remove and check the cylinder block gasket for damage, replace it if necessary. GASKET DOWEL PIN 2-12...
  • Page 15 2.2.2 Troubleshooting to Cylinder Block Description Damage Form Trouble Service Too much oil dirt and dusts on Poor cooling and overheating engine Clear away oil dirt and dusts the radiating fins Seriously deformation of upper Air leaks between cylinder head and cylinder block. Engine fails Grind the end face of cylinder head or end face of cylinder block or is hard to start.
  • Page 16 2.2.3 Reference List of Standard Value and Limit Value for Cylinder Block Maintenance Description Test Item Standard Value Limit Value Service Picture Cylinder block bore Replace when beyond Φ53.5～Φ53.51 Φ53.6 Bore ID the limit value Cylinder Block Flatness on upper & lower faces of cylinder Replace when beyond...
  • Page 17 Guide pulley diameter Replace when beyond Φ45 Φ44 Guide Pulley Diameter the limit value Roller 滚轮直径 diameter Replace when beyond Φ47 Φ46 Roller Diameter the limit value 2-15...

  • Page 18: Valve Train

    2.3 VALVE TRAIN 2.3.1 Removal, Installation and Maintenance 1) Check the intake & exhaust valves for air leakage, grind the sealing face of 3) Remove and check the valve springs for deformation and wear, replace the valves if necessary. spring if it is worn or out of elasticity. VALVE CLIP VALVE SPRING VALVE SPRING...
  • Page 19 5) Remove and check the intake & exhaust valves for wear, replace them if 7) Measure the valve cone, replace it if values are beyond the service limit necessary. (upper valve zone: 32° , lower valve zone: 60° , valve seat face: 45° , valve margin width: 1.6mm).
  • Page 20 9) Check the timing driven sprocket for wear, replace it if necessary. 11) To adjust the valve clearance, unscrew the valve cover firstly. Tightening torque: 8~12N· m VALVE COVER 10) Measure the cam lobe length by means of a micrometer, replace it if it is out 12) Unscrew the plug and view-hole plug from the engine left cover.
  • Page 21 13) Adjust the clearance of intake & exhaust valves to 0.03~0.06mm, tighten up 15) Unscrew the nut of magneto rotor to pull out the rotor. the adjusting nut. Tightening torque: 6~10N· m Tightening torque: 40~50N· m 14) Unscrew the bolt to remove the left crankcase cover. Tightening torque: 8~12N·...
  • Page 22 17) Remove and check the tensioning wheel for wear, replace it if necessary. 19) Remove the tensioning rod and check its head for wear, replace it if its OD exceeds service limit Φ11.94mm. 18) Remove the timing chain, check its stretch and wear, replace it if necessary. 2-20...
  • Page 23 2.3.2 Troubleshooting to Valve Train Description Damage Form Trouble Service Not smooth gas inlet and outlet. Engine lacks power. Large noises from Excessive wear of cam Replace the cam valve train Valve Train Excessive wear of camshaft Hole-to-shaft clearance is too large. Abnormal sound from cam Replace the camshaft Timing Chain Loose...
  • Page 24 2.3.3 Reference List of Standard Value and Limit Value for Valve Train Maintenance Description Test Item Standard Value Limit Value Service Picture Height of intake valve lobe Height of intake valve Replace when beyond 32.25～32.37 32.15 lobe the limit value Camshaft Height of exhaust Assembly...
  • Page 25 Adjust valve clearance Intake valve clearance 0.03～0.06 0.10 when beyond the limit value Valve clearance Diameter of Intake Valve Diameter of intake Replace when beyond intake valve Φ4.975～Φ4.99 Φ4.950 valve the limit value Diameter Replace when beyond Runout of valve stem 0～0.01 0.03 the limit value...
  • Page 26 Adjust valve clearance Exhaust valve 0.03～0.06 0.10 when beyond the limit clearance value Valve clearance Exhaust Valve Diameter of Diameter of exhaust Replace when beyond Φ4.915 Φ4.955～Φ4.97 exhaust valve valve the limit value Diameter Replace when beyond Runout of valve stem 0.03 0～0.01 the limit value...
  • Page 27 Free height Replace when beyond Valve Spring Free height 29.7～30.7 27.7 the limit value Diameter of addendum circle Timing Driven Diameter of addendum Replace when beyond Φ67～Φ67.6 Φ66.5 Sprocket circle the limit value 2-25...

  • Page 28: Crankcase

    2.4 CRANKCASE 2.4.1 Removal, Maintenance and Installation 3) Check the right crankcase cover gasket for damage, replace it if necessary. 1) Unscrew the drain bolt to empty the engine oil thoroughly. Tightening torque: 20~30N· m GASKET DRAIN BOLT 2) Unscrew the tightening bolt M6 from right crankcase cover, slightly tap the 4) Configuration of right crankcase cover assembly is shown as follows.
  • Page 29 5) Check the oil seal of starting shaft for wear and damage, replace it if 7) Unscrew the view-hole plug, remove the O-ring and check it for wear, necessary. replace it if necessary. VIEW-HOLE PLUG O-RING OIL SEAL 6) Unscrew the bolt to remove the left crankcase cover. 8) Remove and check the left crankcase cover gasket, replace it if necessary.
  • Page 30 9) Unscrew the nut from the magneto rotor and pull out the rotor. 11) Remove the starting chain, tensioning plate, guide plate and starting clutch Tightening torque: 40~50N· m sprocket, unscrew the bolt to remove the plate cover and seal ring. Tightening torque: 8~12N·...
  • Page 31 13) Check the plate cover seal ring for damage, replace it if necessary. 15) Remove the tensioning rod, check its head for wear, replace it if OD exceeds the service limit (Φ11.975mm). MAGNETO O-RING MAGNETO O-RING II 合 14) Remove the tensioning wheel and check it for wear, replace it if necessary. 16) Remove and check the timing chain for stretch and wear, replace it if necessary.
  • Page 32 17) Unscrew the crankcase closing bolt and screw of gear indicator compressing plate. Tightening torque: 8~12N· m CLOSING BOLT SCREW OF GEAR INDICATOR COMPRESSING PLATE 2-30...
  • Page 33 2.4.2 Troubleshooting to Crankcase Description Damage Form Trouble Service Cracks on crankcase Oil leaks from crankcase Repair or replace Damaged closing thread Oil leaks from joint of left crankcase and right crankcase. Repair or replace Engine fails or is hard to start. Engine lacks power and has Repair the thread hole or replace the Damaged cylinder thread Crankcase...
  • Page 34 2.4.3 Reference List of Standard Value and Limit Value for Crankcase Maintenance Description Test Item Standard Value Limit Value Service Picture Tensioning Replace when rod OD Φ11.975 Φ11.985～Φ12 Tensioning Rod Tensioning rod OD beyond the limit value Length of starting chain (62 links when Replace when 387.35~387.92...

  • Page 35: Transmission

    2.5 TRANSMISSION Clutch 2.5.1 Removal, Maintenance and Installation 1) Remove and check the gasket of right crankcase cover for wear. Replace it if 3) Check the O-ring of clutch adjusting bolt for damage. Replace it if necessary. necessary. O-RING GASKET 2) Check the separating tappet of clutch for wear.
  • Page 36 5) Remove and check the clutch operating arm and separating cam plate for 7) Remove the tightening screw (M5) from the auto clutch cover plate. wear. Replace them if necessary. (Tightening torque: 6-10N· m) SCREW (M5) SEPARATING CAM PLATE OPERATING ARM 6) Pull out the clutch bearing, check the bearing for wear and replace it if 8) Check the auto clutch cover plate and its gasket for damage.
  • Page 37 9) Remove the tightening bolt (M6) from the oil box. 11) Remove the snap ring of auto clutch main body. (Tightening torque: 8-12N· m) CLUTCH MAIN BODY AUTO CLUTCH MAIN BODY BOLT 10) Unscrew the locknut from the clutch, check its thread for damage and 12) Remove the snap ring from the auto clutch drive plate assembly.
  • Page 38 13) Check the snap ring, block, gasket, washer and main body of auto clutch for 15) Unscrew the bolt (M6) from the clutch end cover. (Tightening torque: damage. Replace the block spring if it is out of elasticity. 8-12N· m) CLUTCH DAMPING CLUTCH SPRING...
  • Page 39 17) Remove and check the clutch pressing disc for damage, replace it if 19) Remove the clutch drive plate and driven plate (friction plate), and measure necessary. their thicknesses with a caliper. Replace the plates if they exceed the service limits (2.8mm &...
  • Page 40 2.5.2 Troubleshooting to Clutch Description Cause Fault Remedy The drive disc grooves are worn into Clutch is slipping, not disengaged thoroughly Trim the grooves with a saw or replace Clutch drive disc serrated shape. with a loud noise. the drive disc. Clutch drive plate &...
  • Page 41 Gearshift Mechanism 2.5.3 Removal, Maintenance and Maintenance 1) Unscrew the bolt (M6) to remove the gear locating plate, check the locating 3) Unscrew the bolt (M6) of gear indicator from the gearshift cam assembly, plate for damage, and replace it if necessary. Replace the spring if it is inelastic. and remove the gear indicator contact.
  • Page 42 5) Unscrew the tightening bolt (M6) from the crankcase to remove the right 7) Remove the gearshift cam assembly, main shaft and countershaft comp. crankcase assembly. Check the crankcase gasket for damage, replace it if necessary. (Tightening torque: 8-12N· m) MAIN SHAFT COUNTERSHAFT GEARSHIFT CAM...
  • Page 43 9) Check the drum and fork groove of gearshift cam for wear, replace the drum 11) Check the gears of main shaft and countershaft for wear, and replace them if if it exceeds the service limit (Φ33.93mm). deep pits or missing teeth occur. COUNTERSHAFT MAIN SHAFT 10) Check the main shaft and countershaft, and replace them if their matching...
  • Page 44 13) Remove and check the countershaft 3rd gear and its washer for wear. 15) Check the countershaft 1st gear for wear, and replace the gear if the bore Replace them if the bore exceeds the service limit (Φ20.073mm). exceeds the service limit (Φ23.073mm). 14) Check the countershaft 2nd gear for wear, and replace it if necessary.
  • Page 45 17) Remove and check the main shaft 4th gear and spline washer for wear, and 19) Remove and check the main shaft 2nd gear for wear, and replace it if the replace them if the bore exceeds the service limit (Φ17.075mm). bore exceeds the service limit (Φ17.075mm).
  • Page 46 21) Check the inner spline washers and snap rings on the main shaft for deformation, and replace them if necessary. 2-44...
  • Page 47 2.5.4 Troubleshooting to Gearshift Mechanism Description Cause Fault Remedy The teeth surfaces have pits, teeth are broken Abnormal noise occurs when the gearbox is Replace the gear. or gear inner hole is severely worn. working. It's difficult to gearshift. The meshing face of gear end is worn into an It's easy to disengage.
  • Page 48 2.5.5 Reference List of Standard Value and Service Limit Value for Transmission Mechanism Description Test Item Standard Value Limit Value Service Picture THICKNESS Replace if it Auto clutch driven Thickness 2.6-2.9 2.35 exceeds the plate limit value. Replace if it Auto clutch drive Thickness 1.6-1.75...
  • Page 49 THICKNESS Replace if it Auto clutch drive Thickness 3.35-3.65 exceeds the plate II limit value. Thickness 1.45-1.55 Replace if it Auto clutch pressing exceeds the AUTO plate CLUTCH limit value. PRESSING PLATE Flatness 0-0.1 Replace if it Auto clutch spring Free height 17.7-18.3 14..2...
  • Page 50 Φ34-Φ34.039 Φ34.06 Inner hole diameter INNER HOLE Replace if it DIAMETER Fork exceeds the limit value. Fork thickness 4.85-4.95 FORK THICKNESS Replace if it Gearshift cam Groove width 6.05-6.15 6.18 exceeds the limit value. GROOVE WIDTH Replace if it Φ17.016-Φ17.043 Φ17.075 Main shaft 2nd gear Inner hole diameter...
  • Page 51 Replace if it Φ17.016-Φ17.043 Φ17.075 Main shaft 4th gear Inner hole diameter exceeds the limit value. MAIN SHAFT 4TH GEAR Replace if it Φ23.02-Φ23.041 Φ23.073 Countershaft 1st gear Inner hole diameter exceeds the limit value. COUNTERSHAFT 1ST GEAR Replace if it Φ20.02-Φ20.041 Φ20.073 Countershaft 3rd gear...

  • Page 52: Crank Mechanism

    2.6 CRANK MECHANISM 2.6.1 Removal, Maintenance and Installation 1) Check the main shaft bearing, countershaft bearing and crankshaft bearing. 3) Remove the crank connecting rod and the construction is shown as the Replace them if they're severely worn. following figure. 2) The construction of crank connecting rod, main shaft comp., countershaft 4) Measure the gap of connecting rod big end with thickness gauge and comp.
  • Page 53 5) Check the timing drive sprocket of connecting rod and replace it if necessary. 7) Clear away the carbon deposit on the piston top. Make sure the tooth valleys between any two teeth are aligned with the center line of crankshaft key slot. And check the left and right bearings of crankshaft for wear.
  • Page 54 9) Measure the O.D. at the piston skirt 10mm from the piston bottom. Replace the piston if it exceeds the service limit (Φ53.15mm). 10) Measure the width of piston ring groove. Replace the piston, if it exceeds the service limit (Piston ring I&II: 0.89mm, Oil ring: 2.09mm). 2-52...
  • Page 55 2.6.2 Troubleshooting to Crank Mechanism Description Cause Fault Remedy Carbon deposit on the piston top Engine overheats. Clear away carbon deposit. Engine fails or is hard to start. Engine lacks power Carbon deposit in the piston ring with thick blue smoke exhausting from the groove exhaust pipe.
  • Page 56 2.6.3 Reference List of Standard Value and Service Limit value for Crank Mechanism Description Test Item Standard Value Limit Value Service Picture PISTON SKIRT DIAMETER Diameter of Replace if it exceeds the Φ53.475-Φ53.485 Φ53.440 piston skirt service limit. Piston CYLINDER Cylinder Replace if it exceeds the MATCHING...
  • Page 57 PIN HOLE I.D. I.D. of pin Replace if it exceeds the Φ13.002-Φ13.008 Φ13.05 hole service limit. Piston PISTON ring I& 0.02-0.055 0.09 RING I & II Gap between piston ring Replace if it exceeds the Piston OIL RING and piston service limit.
  • Page 58 Piston ring 0.10-0.25 OPEN GAP (WHEN Replace if it exceeds the Close gap ASSEMBLED) service limit. Piston ring 0.25-0.35 Piston ring set Piston ring Approx. 6.2 Replace if it exceeds the Open gap OPEN GAP (NOT service limit. Piston ring Approx.6.6 ASSEMBLED) BIG-END BACKLASH...

  • Page 59: Starter

    2.7 STARTERS Kick-starter 2.7.1 Removal, Maintenance and Installation 1) Remove and check the starting shaft spring and spring seat. Replace them if 3) Remove the starting shaft assy. they are worn or deformed. STARTING RETURN SPRING STARTING SHAFT SPRING SEAT 2) Check the starting return spring for elasticity.
  • Page 60 5) Remove the starting shaft spring and ratchet. Replace them if they are 7) Remove and check the starting shaft circlip, starting ratchet, starting return severely deformed or worn. spring and washer. Replace them if they're deformed or worn. STARTING SHAFT SPRING RATCHET RATCHET STARTING RETURN SPRING...
  • Page 61 2.7.2 Troubleshooting to Kick-starter Description Cause Fault Remedy The spline slips with the starting lever Starting lever Slips in starting Replace the starting lever. connected. Gear is worn. Starting gear Replace the gear. Gear is worn or damaged. Difficult to start Ratchet is severely worn.
  • Page 62 Electric starter 2.7.3 Removal, Maintenance and Installation 1) Unscrew tightening bolt (M6) of starting motor. (Tightening torque 8-12N· m) 3) Check the O-ring on starting motor and replace it if it's broken. STARTING MOTOR ASSY. O-RING 2) Knock the starting motor assy. with a plastic hammer and remove it. 4) Check the starting chain for stretch and wear.
  • Page 63 5) Check the tension plate and the guide plate for wear. Replace them if they are 7) Check the starting clutch sprocket weldment for wear. Replace it if it's severely worn. severely worn. TENSION PLATE STARTING CLUTCH SPROCKET COMP. GUIDE PLATE 8) Check the body, roller and spring of the starting clutch for wear.
  • Page 64 9) Remove the bolt (M6) of magneto stator coil from the left crankcase cover (Tightening torque: 8-12N· m). Check and replace it if it's damaged. MAGNETO STATOR COMP. 2-62...
  • Page 65 2.7.4 Troubleshooting to Electric Starter Description Cause Fault Service Carbon brush is excessively worn. Starting motor lacks power or fails to work. Replace the starting motor. The carbon brush spring is broken or Starting motor lacks power. inelastic. The rotor commutator surface is fouled. Starting motor The rotor commutator surface is burnt or damaged.

  • Page 66: Lubrication System

    2.8 LUBRICATION SYSTEM 2.8.1 Removal, Maintenance and Installation 1) Remove the cap nut from the engine. (Tightening torque 10-14N· m) 3) Check the oil passage in cylinder head for block. CAP NUT 2) Step the starting lever and start the engine and check the copper washer for 4) Check the oil passage in cylinder block for block.
  • Page 67 5) Check the crankcase oil passage and clean it. 7) Unscrew the bolt (M6) on right crankcase cover, and remove the right crankcase cover. (Tightening torque: 8-12N· m) OIL PASSAGE HOLE 6) Unscrew the drain plug (Tightening torque: 20-30N· m) and empty the engine 8) Check the sight glass for oil leaks and replace it if necessary.
  • Page 68 9) Remove the oil strainer on right crankcase assy. and clean it. Replace it if it's 11) Check the auto clutch cover plate and its gasket. Replace them if they're broken. broken. GASKET CLUTCH COVER PLATE OIL STRAINER 10) Check the auto clutch body. Replace and clean it if it's broken. 12) Unscrew the tightening screw (M6) of oil pump.
  • Page 69 13) Remove the oil pump. 15) Check the drive sprocket, snap ring and washer of oil pump for wear. Replace them if they're severely worn. OIL PUMP DRIVE SPROCKET 14) Remove the snap ring of the oil pump drive sprocket. 16) Unscrew the fixing bolts of oil pump.
  • Page 70 17) Remove the oil pump cover and clean it. OIL PUMP BODY OIL PUMP COVER OIL PUMP OUTER ROTOR OIL PUMP INNER ROTOR 18) Check the top and bottom cover of oil pump. Replace the oil pump inner and outer rotors if they are broken or severely worn. OIL PUMP OUTER ROTOR OIL PUMP INNER ROTOR 2-68...
  • Page 71 2.8.2 Troubleshooting to Lubrication System Description Cause Fault Service Replace the oil pump drive Oil pump drive sprocket Severely worn Engine lacks power, overheats or is severely worn. sprocket. Low oil supply. Engine lacks power or overheats. Parts are Lubrication system Oil passages are blocked.
  • Page 72 5) Unscrew the engine cap nut M7. 7) Check the cylinder head left cover, valve cover and bolt M6, replace them if Tightening torque: 12~16N· m necessary. BOLT GASKET BOLT M6 VALVE LEFT COVER COVER CAP NUT M7 6) Remove the cylinder head assembly. 8) Check the gasket and valve cover seal ring, replace them if necessary.
  • Page 73 9) Configuration of cylinder head assembly is shown as follows. 11) Remove the rocker arm shaft and valve rocker arm. ROCKER ARM SHAFT 10) Unscrew and remove the press plate bolt M6 of rocker arm shaft. 12) Remove the camshaft assembly and check it for wear, replace it if (Tightening torque: 8~12N·...
  • Page 74 13) Check the intake and exhaust rocker arm and shaft for deformation and wear, 15) Measure the width of valve contact surface, replace the cylinder head and replace it if shaft OD＜Φ9.94mm. valve if it is beyond the limit (＞1.6mm). VALVE ROCKER ARM SHAFT VALVE ROCKER ARM...
  • Page 75 17) Measure the bore of valve guide, replace it if value exceeds the service limit (＞Φ5.03mm). 18) Unscrew the spark plug M10× 1, clear carbon deposits on it. Tightening torque: 10~20N· m SPARK PLUG...
  • Page 76 2.1.2 Troubleshooting to Cylinder Head Description Damage Form Trouble Service Too much oil dirt and dusts on the Poor cooling or overheating engine Clear away oil dirt and dusts radiating fins Carbon deposits in the combustion Engine overheats Clear away carbon deposits chamber Damaged threaded hole of spark Air leakage between spark plug and cylinder head,...
  • Page 77 Engine fails or is hard to start. Engine lacks power, has Adjust by slightly bend the side electrode till Improper gap between two electrodes unstable idle speed. the gap is 0.65-0.75 mm Electrodes link by carbon deposits Engine fails to start. Clear away carbon deposits Too much carbon deposits or oil dirt Engine fails or is hard to start.
  • Page 78 2.1.3 Reference List of Standard Value and List Value for Cylinder Head Maintenance Description Test Item Standard Value Limit Value Service Picture Flatness Flatness of cylinder face 0～0.05 0.08 Width of Replace when valve seat Width of valve seat Cylinder Head beyond the 0.9～1.1 sealing face...
  • Page 79 Replace when Diameter of Diameter of rocker arm Φ10～Φ10.022 Φ10.05 Cylinder Head beyond the rocker arm shaft bore limit value shaft bore Spark plug Adjust gap Spark Plug Spark plug gap 0.8～0.9 when beyond the limit value Replace when Φ9.972～Φ9.987 Φ9.94 Rocker Arm Shaft OD of rocker arm shaft...

  • Page 80: Chapter 3 Chassis

    CHAPTER 3 CHASSIS 3.1 FRAME BODY 3.1.1 Motorcycle Identification 3.1.2 Maintenance of Frame 1) VIN The vehicle identification number (VIN) is engraved on Description Damage Form Trouble Service the upper face of handrail mounting bracket. Correct or Deformed or Frame Off-tracking replace the broken...
  • Page 81 3.1.3 Maintenance of Frame and Accessories  Removal, Installation and Maintenance 3) Adjust the travel of rear brake pedal at the rear brake level if travel exceeds 1) Structure of frame is shown below. Check the welding parts and frame. the service limit (20~30mm).
  • Page 82 5) Check the front fender for break, replace it if necessary. 7) Check the front footrest pedal for damage, replace it if necessary. FRONT FENDER FRONT FOOTREST PEDAL 6) Check the rear fender for break, replace it if necessary. 8) Check the rear footrest pedal for damage, replace it if necessary. REAR FOOTREST PEDAL REAR FENDER...
  • Page 83 9) Check the center stand for deformation, replace it if necessary. 11) Check the handrail for break, replace it if necessary. HANDRAIL CENTER STAND 10) Check the side stand for deformation, replace it if necessary. 12) Check the seat cushion for break, replace it if necessary. SEAT CUSHION SIDE STAND...
  • Page 84 13) Check the windshield for break, replace it if necessary. 15) Check the rear-mid connecting plate for break, replace it if necessary. REAR-MID CONNECTING PLATE WINDSHIELD 14) Check the rear panel for break, replace it if necessary. REAR PANEL...

  • Page 85: Suspension System

    3.2 SUSPENSION SYSTEM 3. 2.1 Removal, Installation and Maintenance of Steering Bar 1) Turn the steering bar and check it for proper functioning. 3) Disassemble the steering bar pipe and check it for deformation, correct or replace it if necessary. HANDLE 2) If necessary, disassemble the steering system to check.
  • Page 86 5) Unscrew the adjusting nut of steering stem. 7) Extract the steering stem, check the top cover and bottom race of lower bearing of steering stem for wear, replace it if necessary. 6) Check the top cover and bottom race of upper bearing of steering stem for 8) Before installing the steering stem, apply a layer of grease to the top cover wear, replace the bearing if necessary.
  • Page 87 9) Before installing the steering stem, apply a layer of grease to the top cover 11) Tighten up the steering stem locknut. and bottom race of upper bearing. 10) Tighten up the steering stem locknut.
  • Page 88 3.2.2 Troubleshooting to Steering Stem Description Damage Form Trouble Service Operation of steering handle is stiff ; little Turn the adjusting nut by a wrench until the Adjusting nut of steering stem is over gaps between bearing and upper cover, steering stem turns flexibly without radial play tightened bearing and bottom race...

  • Page 89: Front Suspension

    3.3 FRONT SUSPENSION 3.3.1 Removal, Installation and Maintenance of Front Suspension 1) Unscrew the fixing bolt of brake hose from the front fender. 3) Remove the front fender and front shock absorber. 2) Unscrew the locknut of front axle and fixing bolt of brake caliper, pull out 4) Unscrew the drain bolt from the front shock absorber and drain the damping the front axle and remove the front wheel.
  • Page 90 5) Remove the dust cover and clip, extract the bottom case. 7) Extract and check the damping spring for wear, replace it if necessary. 6) Remove and check the oil seal for wear, replace it if necessary. 8) Measure the inner diameter of bottom case, replace it if it exceeds its service limit.
  • Page 91 9) Measure the free length of shock absorber spring, replace it if it is out of the service limit 316.5±1.5 mm. 10) Pour about 60± 1ml damping oil into the tube. 3-12...
  • Page 92 3.3.2 Troubleshooting to Front Shock Absorber Description Damage Form Trouble Service The front shock absorber is too soft or Front shock absorber Non-elastic or broken abnormal sound comes out of the bottom Replace the spring spring case Bent or deformed Off-track in running Correct or replace the front shock absorber Damaged or scratched working...

  • Page 93: Rear Suspension

    3.4 REAR SUSPENSION 3.4.1 Removal, Installation and Maintenance of Rear Suspension 1) Check the rear wheel for swing, adjust or replace the rear fork sleeve if 3) Check the rear shock absorber spring; check the rear shock absorber for oil necessary.
  • Page 94 3.4.2 Troubleshooting to Rear Suspension Description Damage Form Trouble Service The spring is non-elastic or broken. The rear shock absorber is too soft. Replace the spring Rear shock absorber Oil leaks from the rear shock absorber. The rear shock absorber is too soft. Replace the rear shock absorber The piston rod is bent, deformed or The rear shock absorber is hard.

  • Page 95: Front And Rear Wheels

    3.5 FRONT AND REAR WHEELS 3.5.1 Maintenance of Wheels 1) Unscrew the front axle locknut to remove the front wheel. 3) Check the speedometer seal ring for wear, replace it if necessary. 2) Remove and check the front axle bush for wear, replace it if necessary. 4) Check the brake shoes for wear, replace the shoes as a set if necessary.
  • Page 96 5) Remove and check the front axle oil seal for wear, replace it if necessary. 7) Remove the rubber dust cover of drain hose of front brake caliper, loosen the locknut; hold the front brake lever, and tighten the locknut until oil comes out from the drain hose (while not releasing the front brake lever).
  • Page 97 9) Finally, repeatedly step and release the rear brake pedal until the operation 11) Unscrew the adjusting nut from the chain adjuster and pull out the rear axle. force is suitable (less than 350N). 10) Unscrew the locknut from the rear axle. 12) Remove the rear axle bush and oil seal, check the oil seal and replace it if necessary.
  • Page 98 13) Unscrew the nut from the sprocket hub assembly, remove and check it for 15) Check the bearing of rear axle for wear, replace it if necessary. wear, replace it if necessary. BEARING 14) Check the tyre for wear, replace it if it exceeds 2mm of the service limit. 3-19...
  • Page 99 3.5.2 Troubleshooting to Front and Rear Wheels Description Damage Form Trouble Service Shortened service life of bearing, incorrect Front axle oil seal is worn. Replace the front axle oil seal count of speedometer Front wheel Brake shoes are worn. Decreased braking effect Replace the brake shoes Discharge air in the front hydraulic brake as specified in Poor braking performance...

  • Page 100: Intake System And Exhaust System

    3.6 INTAKE SYSTEM AND EXHAUST SYSTEM 3.6.1 Removal, Installation and Maintenance of Intake System 1) Unscrew the mounting screw to remove the windshield, and disassemble the 3) Remove and check the air cleaner filter strainer for damage, replace it if air cleaner.
  • Page 101 5) Check the air cleaner housing, clear away dust on it and replace it if necessary. 3-22...
  • Page 102 3.6.2 Troubleshooting to Air Cleaner Description Damage Form Trouble Service Remark 1. Remove the air cleaner element as 3.6.1; Engine is hard to start, engine lacks 2. Blow the dust on the element surface off, replace Too much dust on the power, poor performance at idle Do not clean it with the element if necessary；...
  • Page 103 3.6.3 Removal, Installation and Maintenance of Exhaust System 1) Unscrew the fixing nut that connects the exhaust muffler with the engine. 3) Check the exhaust muffler gasket, replace it if necessary. 2) Remove the exhaust muffler, check the mounting plate for break, repair or 4) Shake the exhaust muffler and check the interior, replace it if necessary.
  • Page 104 3.6.4 Troubleshooting to Exhaust Muffler Description Damage Form Trouble Service Remark Exhaust muffler Loud noises from the exhaust Replace the gasket after each Broken gasket Replace the muffler gasket gasket system, air leaks from the pipe. disassembly Broken muffler housing Loud noises from the exhaust Replace the exhaust muffler and mounting bracket...

  • Page 105: Chapter 4 Electrical Components And Meter

    CHAPTER 4 ELECTRICAL COMPONENTS AND METER ●Location Distribution of Electrical Components on The Vehicle FUEL PUMP&FUEL SENSOR BATTERY&FUSE BOX DIMMER/TURN SIGNAL/EMERGENCY/HORN SW. STARTER BUTTON METER FR. BRAKE SW. TAILLIGHT&RR. REFLECTOR RR. WINKER, LH/RH IGNITION SW. RR. BRAKE SW. STARTING MOTOR RECTIFIER SPARK PLUG&SPARK PLUG CAP HORN...
  • Page 106 STARTING RELAY HEADLIGHT FR. WINKER, LH/RH FLASHING RELAY IGNITION COIL SPEED SENSOR MAGNETO&GEARSHIFT SW.
  • Page 107 ●Electric diagram...

  • Page 108: Charging System

    CHARGING SYSTEM The vehicle is equipped with a battery 12V and a set of charging system as electric power. ● The charging system consists of: 1)Battery 12V6Ah 2)Magneto (permanent magnet alternator): rotor and stator (including charging/lighting coil and exciter coil) 3)Rectifier: 3-phase full wave 4)Fuse: cartridge fuse 15A with a spare one.
  • Page 109 The charging voltage of rectifier should be within 13V～15V. If it's less than 13V, and the malfunction is determined from the rectifier, replace the rectifier with a new one. Disconnect coupler of the magneto charging/lighting coil to main cable and check it for short circuit, broken circuit or poor connection. Repair or replace it if necessary.
  • Page 110 Remove the magneto rotor flywheel and check the rotor for magnetism. Replace it if necessary BATTERY FUSE MAGNETO ROTOR Check the battery voltage. If it's below 12V, recharge the battery in time. Check the fuse and replace it with same specification (15A) one if necessary. It's forbidden to take other materials, other ways instead or remove the fuse to connect with the vehicle circuit, which may cause the vehicle burning.

  • Page 111: Ignition System

    IGNITION SYSTEM Ignition: EFI ignition, please refer to Chapter 5. ●The ignition system consists of battery (D.C. 12V), magneto, exciter coil, ECU, ignition coil, spark plug and so on. The function of the ignition system is to supply a sufficiently high voltage to the spark plug at a certain moment, generating a strong enough electric spark between the two electrodes of the spark plug to ignite the compressed mixture, thus enabling the engine to work.
  • Page 112 Remove the spark plug cap and replace it if necessary. Spark plug cap resistance: 5kΩ±0.5kΩ SPARK PLUG CAP SPARK PLUG METAL POSITIVE HEAD Remove the spark plug cap on the high-voltage wire of the ignition coil, and clamp the high-voltage wire with an insulating clamp at a position of100mm to 150mm away from the end of the high-voltage wire at the spark plug cap.
  • Page 113 If the exciter coil or insulator is damaged, repair or replace it please. Disconnect the coupler of igniter to main cable and check it. Repair or replace it if necessary. Check if the black wire has a voltage of D.C. 12V and if the green wire is well connected with battery (The normal resistance of the wire should be below 0.1Ω).
  • Page 114 Short circuit The engine stop switch is out of work. Replace the faulty switch. Ignition switch/engine stop switch Broken circuit No ignition spark and the engine fails to start. Damaged Replace the ECU. No/weak ignition spark. Engine is hard to start with Short circuit Replace the ignition coil insufficient power or unstable idle speed.

  • Page 115: Signal System And Meter

    SIGNAL SYSTEM AND METER The signal system consists of turn signal switch, dimmer switch, horn button, horn, LED winker, various LED indicator lamps, flashing relay, front position light, taillight assy. (braking light, rear position light), front brake switch, rear brake switch, meter and so on. 4.3.1 Removal, Installation and Maintenance of Signal System Turn on the ignition switch and check the signal system and meter.
  • Page 116 COUPLER OF FRONT WINKER TO METER COUPLER OF HEADLIGH AND FRONT POSITION LIGHT TO METER COUPLER OF TURN SIGNAL SWITCH TO METER COUPLER OF HORN SWITCH TO METER SOCKET OF BRAKING LIGHT AND REAR POSITION LIGHT COUPLER OF METER TO MAIN CABLE COUPLER OF HORN TO METER FR.
  • Page 117 FRONT WINKER REAR WINKER COUPLER OF RR. BRAKE SWITCH TO MAIN CABLE COUPLERS OF BRAKING LIGHT/REAR POSITION LIGHT AND REAR WINKER FUEL PUMP & FUEL SENSOR WIRE HARNESS OF FUEL PUMP & FUEL SENSOR INSTALLATION PORT OF FUEL PUMP & FUEL SENSOR HORN COUPLER OF HORN TO METER COUPLER OF GEARSHIFT SWITCH...
  • Page 118 Check the couplers of horn and horn switch to meter for continuity. Repair or replace them if necessary. Turn the horn sound adjusting screw if there is no/weak horn sound. If the horn is damaged, please replace it with a new one with same specification. Check such couplers of meter, gearshift switch, fuel sensor, etc.
  • Page 119 4.3.2 Troubleshooting to Signal System and Meter Description Damage Form Trouble Symptom Remedy Winker Internal damage The winker are out of work. Repair or replace the light. Front position light The front position light is out of work. Lighting switch and Poor connection, broken circuit The position light or high beam indicator is out of work.

  • Page 120: Lighting System

    LIGHTING SYSTEM The lighting system includes dimmer switch, headlight, LED license light, etc. 4.4.1 Removal, Installation and Maintenance of Lighting System Turn on the ignition switch, and check the lighting system. DIMMER SWITCH COUPLER OF HEADLIGHT TO METER IGNITION SW. Check the battery voltage, fuse and charging system according to the method in charging system, and the voltage should be in normal range.
  • Page 121 necessary. Check the main cable and the internal of ignition switch for continuity, and repair or replace them if necessary. To test the fault: Please disconnect the relative coupler according to the electric diagram, and connect it to a D.C. 12V battery with a multimeter. Then judge if the part is faulty or not.

  • Page 122: Electric Starting System

    ELECTRIC STARTING SYSTEM Electric starting mode: brake starting. The electric starting system includes starting motor, starting relay, ignition switch, electric starter button, grounded cable, front/rear brake switch, battery, fuse etc. In order to start the engine, a DC 12V power supply and a reliable ignition system are necessary. The following is a special introduction to the removal, installation and maintenance of the electric starting system.
  • Page 123 COUPLER OF IGNITION SW. TO MAIN CABLE COUPLER OF MAIN CABLE TO METER FR. BRAKE SW. RR. BRAKE SW. AND ITS COUPLER TO MAIN CABLE COUPLER OF ELECTRIC STARTER BUTTON TO METER If the vehicle fails to electric starting, please check the couplers of electric starter button, front brake switch, etc. to meter, coupler of starting motor positive lead, coupler of meter to main cable and coupler of starting motor positive lead to starting relay, and check the couplers of ignition switch, rear brake switch, starting relay, battery, fuse, engine housing to main cable for continuity.
  • Page 124 The electric starting system has no power, and the Replace the fuse with the same specification Poor connection or the fuse is burnt. Fuse vehicle fails to start. one. The starting motor fails to run or runs abnormally Battery No voltage or voltage is too low Repair or replace the battery.

  • Page 125: Battery And Fuse

    BATTERY AND FUSE CONNECTING WIRE BETWEEN MAIN CABLE BATTERY TO BATTERY POSITIVE ELECTRODE FUSE CONNECTING WIRE BETWEEN MAIN CABLE TO BATTERY NEGATIVE ELECTRODE Measure the battery voltage. If it's below 12V, charge the battery in time. Fuse: 15A, with a spare one. Check the fuse and replace it with same specification (15A) one if necessary. It's forbidden to take other materials, other ways instead or remove the fuse to connect with the vehicle circuit, which may cause the vehicle burning.
  • Page 126 If the vehicle is not used for a long time, the battery will discharge itself and cause insufficient capacity. Please remove the battery, charge it, store it in a cool, ventilated place, and charge the battery every 3 months. After 2 to 3 years of normal use, the battery capacity will also decrease, and it must be recharged to restore the voltage.

  • Page 127: Lights And Horn

    LIGHTS AND HORN 4.7.1 Lights For removal, installation and maintenance of lights, please refer to 4.3 Signal system and meter & 4.4 Lighting system. 1) Adjustment of brake light switch Check the front and rear brake switch for proper function. Turn on the ignition switch, and hold the front brake handle or step on the rear brake pedal, the brake light will be on.
  • Page 128 development for erosion appearing on connectors. For example, the horn sounds late after pushing the button, does not sound, the sound is not crisp, the sound is intermittent and the horn does not sound until the button is pressed again, all of them can be considered as the faults of horn connectors fault. 4-24...

  • Page 129: Chapter 5 Structure And Maintenance Of Efi System

    CHAPTER 5 STRUCTURE AND MAINTENANCE OF EFI SYSTEM 5.1 INTRODUCTION OF EFI SYSTEM 5.1.1 Definition 5.1.3 Working Principle of EFI System By various sensors, the EFI system converts the engine intake air volume, coolant temperature, engine speed, acceleration, deceleration and other operating conditions into electric signals, which are then input to the ECU.

  • Page 130: Configuration And Layout Of Efi Parts

    5.2 CONFIGURATION AND LAYOUT OF EFI PARTS 5.2.1 EFI Parts INJECTOR RELAY FUEL PUMP THROTTLE VALVE BODY 5.2.2 Layout of EFI Parts IAP&IAT SENSOR CYLINDER OIL RAIL OXYGEN SENSOR TEMPERATURE SENSOR...

  • Page 131: Efi Performance And Malfunction

    5.3 EFI PERFORMANCE AND MALFUNCTION 5.3.1 ECU Function ECU is a kind of electronic control integrated device. The optimal fuel injection timing of the engine under various working conditions is stored in the ECU memory. After receiving signals from various sensors, the fuel injection quantity satisfied the engine running state is determined, and the injection time is controlled according to the calculated results.
  • Page 132 ECU Parameters Definition of ECU Pin Item Value Battery voltage range in normal (V) 9~15 Working temperature (℃) -30~80 Storing temperature (℃) -40~90 Malfunction Mode Invalid connector, damaged elements, short-circuit due to water entering, loose and invalid elements due to vibration. NOTE: The pin number is marked according to the digital sequence on back of the ECU plug at the end of main cable.
  • Page 133 5.3.2 Fuel Pump Ambient temperature (℃) -40~80 Function Allowable fuel working temperature (℃) -30~70 Fuel pump is used to deliver fuels from fuel tank to engine at certain pressure and flow rate (as per the different vehicle and engine type).Working condition Malfunction Mode of fuel pump: when start the ignition switch, the fuel pump will run for 3s, if Blocked precise filter, fuel pump fails to rotate, invalid oil pressure regulator,...
  • Page 134 Idle Speed Adjustment 5.3.4 IAP Sensor (1) Target values of adjustment parameter Function RPM: 1300±100r/min (1600±100 r/min for scooter) It is used to monitor the intake Ignition advance angle: -0.2-(+6.0) ° manifold absolute pressure and Cylinder head temp.: 90±3℃ provide engine load information. TEV opening：30°...
  • Page 135 Malfunction Mode 5.3.7 Oxygen Sensor Connecting pipe is blocked, damagesl or falls off; invalid sensor due to Function short-circuit or break-circuit, water entering, mechanical failure. The oxygen sensor is used in the feedback 5.3.5 Stepper Motor system of EFI device. It can realize the closed The stepper motor receives directives from ECU to control the amount of air loop to improve the control accuracy of ECU intake when the engine is idling.
  • Page 136 short-circuit or break-circuit of heating/sensing circuit. Parts Reference Range Trouble Remark 1. 0V (short- circuit 5.3.8 Cylinder/Water Temperature Sensor Unstable idle of oxygen sensor) Function speed, not fluent Large fluctuation 2. 0.44V (open- The cylinder/water temp. sensor is a negative temperature coefficient (NTC) fuel supply, high Oxygen between 0.01-0.99V...
  • Page 137 Characteristic Parameters Characteristic Parameters Item Value Item Value Storing temperature (℃) -40~130 Working voltage (V) 8~16 Running temperature (℃) -40~200 Acceptable internal fuel pressure (kPa) <1100 2.5 ±5% Rated resistance at 20℃ Continuous working temp. of injector (℃) -40~110 Malfunction Mode Resistance range of injector at 20 ℃...
  • Page 138 Malfunction Mode 5.3.12 Engine Speed Sensor Break-circuit or short-circuit of relay, poor contact or failure of relay due to Function vibration. It is used in EFI device to monitor the engine crankshaft speed and output voltage-frequency signals to the electronic controller to make judgments on 5.3.11 Ignition Coil engine’s operating conditions.

  • Page 139: Malfucntion Diagnosis

    5.4 MALFUNCTION DIAGNOSIS 5.4.1 Self-diagnosis Function Sensor MIL Flash Code (1) After the vehicle enters the working state, ECU controls the electronic IAT Sensor system components to work and detects them in real time. Once malfunction occur to the components, the system will turn on the engine MIL to warn. When the system fails, ECU will start the backup function of “emergency control Intake Air Manifold Pressure plan”.
  • Page 140 5.4.3 Diagnosis Reference Value Item Reference Range Fault and Troubleshooting Remark 1. When the angle is large, counterclockwise turn the idle speed bypass screw by 1/4 of a lap, accelerate the throttle 3 times and wait for 15s to It is normal to occasionally check, repeat above operation until it returns to the standard value.
  • Page 141 A fault may occur if the read differs significantly from the actual IAT sensor Vary as the air temperature Replace the sensor temperature. 1. Unstable idle speed, slow response in acceleration; Mounting screw of the sensor 0-80% 2. Opening at idle speed condition shows 0 or 0.39%. cannot rotate freely.

  • Page 142: Troubleshooting

    5.5 TROUBLESHOOTING TROUBLE POSSIBLE CAUSES SOLUTION 1. Check the battery, fuse, system relay, wire harness and No power in the system or at the fuel pump plug emergency switch for normal work. 2. If above components are in good condition, check the ECU. Fuel pump fails to work Damaged fuel pump Replace the fuel pump...
  • Page 143 Poor contact of ignition circuits Check and repair the circuits No spark Large gap between speed sensor (exciter coil) Adjust the gap or broken and rotor convex plate spark ignition Damaged ignition coil or spark plug Replace coil high Creepage of ignition coil output Replace pressure Faulty ECU or poor contact of couplers...
  • Page 144 Battery voltage＜ 12V Check the battery and charging system Poor contact of ECU or injector couplers Check and troubleshooting Check the paper gasket, O-ring, clamp or connecting hose for Air leaks from throttle valve body or connecting hose of inlet pipe air leakage Dirties in throttle valve body or clogged air cleaner Clean off...
  • Page 145 Faulty water/cylinder temp. sensor Check and replace Failure of acceleration at mid/high speed or engine speed drops rapidly when Faulty oxygen sensor Check and replace holding the throttle for about 5s Insufficient fuel pressure of fuel pump Check and replace Poor contact of circuit Check Rectifier is unable to charge...
  • Page 146 Poor contact of spark plug and cap, or water entering in Check and repair Air leaks from oxygen sensor mounting seat Check and repair Running with sudden rush Faulty oxygen sensor Replace Improper TEV opening and abnormal idle gulp air Adjust Air leaks from muffler gasket Repair...

  • Page 147: Chapter 6 Service

    CHAPTER 6 SERVICE 6.1 ROUTINE MAINTENANCE AND ADJUSTMENT 6.1.1 Maintenance of Drive Chain 6.1.3 Fuel System Check the drive chain for wear and slack. Lubricate the chain if it seems to be FUEL TANK dry. Support the motorcycle with center stand, press the chain between two sprockets to check its slack.
  • Page 148 6.1.3.2 Troubleshooting to Fuel Tank Description Damage Form Trouble Service Remark Cracks on the fuel tank due to Fuel tank leaks. Repair or replace erosion Fuel Tank No fuel supply, engine fails to start. Clean the vent of fuel cock Vent of fuel cock is clogged.

  • Page 149: Pre-Ride Inspection

    6.2 PRE-RIDE INSPECTION Check the following before each ride: 1. Engine oil level——Add engine oil if necessary, check for leakage. 2. Fuel level——Refuel if necessary, check for leakage. 3. Front and rear brakes——Check for operation, adjust free play if necessary. 4.
  • Page 150 6.3.2 Maintenance Schedule ODOMETER READING, km (Note ②) FREQUENCY Item SERVICE ITEM Period 1,000km 4,000km 8,000km 12,000km Note · Ⅰ Ⅰ Ⅰ Fuel line system · Fuel filter · Ⅰ Ⅰ Ⅰ Ⅰ Throttle operation system Note ① Air cleaner element Ⅰ...

  • Page 151: 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...