Longjia 3J4 Service Manual
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Longjia 3J4 Service Manual

4-stroke 125cc
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LJ1P52QMI(3J4)
4- STROKE 125cc
SERVICE MANUAL

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Summary of Contents for Longjia 3J4

  • Page 1 LJ1P52QMI(3J4) 4- STROKE 125cc SERVICE MANUAL...

  • Page 2: Table Of Contents

    CONTENTS CONTENTS 01 SPECIFICATION / TROUBLESHOOTING 02 MAINTENANCE INFORMATION 03 LUBRICATION SYSTEM 04 FUEL SYSTEM 05 REMOVAL OF ENGINE 06 CYLINDER HEAD & VALVE 07 CYLINDER & PISTON 08 V BELT DRIVING SYSTEM / KICK START SYSTEM 09 TRANSMISSION GEAR BOX 10 A.C.

  • Page 3: Specification / Troubleshooting

    1 SPECIFICATION / TROUBLESHOOTING SPECIFICATION ................1-1 ENGINE TORQUE VALUE ............... 1-2 TORQUE STANDARD REFERENCE ..........1-3 TROUBLE DIAGNOSIS ..............1-4 SPECIFICATION： Maker Longjia Model Auto Centrifugal Type 4-Strokes Clutch Clutch Installation and Vertical, below Transmission arragement center incline 80 degree...
  • Page 4 1 SPECIFICATION / TROUBLESHOOTING Engine Torque Value： Project Quantity Teeth Size Torque Value Remark (mm) (N.m) Cylinder head cover bolts 8-12 Cam holder nuts 18-22 Apply oil to the screw Cylinder/cylinder head two-ends Lock on crankcase 7-10 bolts side torque Cylinder head left bolt 8-12 Valve adjusting fixing nut...
  • Page 5 1 SPECIFICATION / TROUBLESHOOTING Torque Standard Reference： Species Locking Torque Species Locking Torque 5mm bolt、nut 4.5-6.0N.m 3mm bolt 0.5-0.8N.m 6mm bolt、nut 8-12N.m 4mm bolt 1-1.5N.m 8mm bolt、nut 18-25N.m 5mm bolt 3.5-5N.m 10mm bolt、nut 6mm bolt、Disk nut 30-40N.m 8-12N.m 12mm bolt、nut 6mm Disk bolt、nut 50-60N.m 10-14N.m...
  • Page 6 1 SPECIFICATION / TROUBLESHOOTING TROUBLE DIAGNOSIS: A. ENGINE HARD TO START OR CAN NOT START Check and adjustment Fault condition Probable causes Fuel Injector test No fuel in fuel tank Check if the pipes are clogged. Check fuel injector is normal Malfunction of fuel pump Loosen or damaged fuel pump Fuel injector abnormal...
  • Page 7 1 SPECIFICATION / TROUBLESHOOTING B THE SPEED IS WEAK Check and adjustment Fault condition Probable causes Try gradual acceleration and check engine speed Air cleaner clogged Poor fuel supply Exhaust pipe clogged Lines in fuel tank evaporation Engine speed can be Engine speed can not be system clogged increased...
  • Page 8 1 SPECIFICATION / TROUBLESHOOTING C. POOR ENGINE OPERATION (ESPECIALLY AT LOW AND IDLE SPEED) Check and adjustment Fault condition Probable causes Check ignition timing 1.Incorrect ignition timing 2.ECU is no good Normal Abnormal Check oil injector 1.Rich mixture 2.Lean mixture Good Poor 1.Spark plug fouled...
  • Page 9 1 SPECIFICATION / TROUBLESHOOTING D. ENGINE FAILURE (HIGH SPEED) Check and adjustment Fault condition Probable causes Check ignition timing 1.Malfunction of AC gernator 2.Malfunction of ECU Normal Abnormal Check for fuel supplying system 1.Insufficient fuel in fuel tank 2.Fuel filter clogged Good Poor 3.Restricted fuel tank vent...
  • Page 10 1 SPECIFICATION / TROUBLESHOOTING E CVT DRIVING WHEEL/DRIVEN WHEEL FAULT PROBABLE CAUSES CONDITIONS 1.Drive belt worn out or deformed 2.Drive face boss ,movable drive face Engine can be started but assy damaged motorcycle can not be moved. 3.Driven pulley spring broken 4.Clutch weight lining broken 5.Transmission gear damaged Engine running and misfire as...

  • Page 11: Maintenance Information

    2 MAINTENANCE INFORMATION PERIODICAL MAINTENANCE SCHEDULE ..........2-2 LUBRICATION SYSTEM ................2-3 CLEANING THE OIL STRAINER ..............2-3 GEAR OIL ...................... 2-4 FULE SYSTEM ....................2-4 AIR CLEANER ....................2-5 VALVE CLEARANCE ADJUSTMENT ............2-5 VALVE CLEARANCE INSPECTION AND ADJUSTMENT ......2-6 CHECK ELECTRONIC FUEL INJECTION SYSTEM ........

  • Page 12: Periodical Maintenance Schedule

    Code: I ~ Inspection, cleaning, and adjustment R ~ Replacement C ~ Cleaning (replaced if necessary) L ~ Lubrication Have your motorcycle checked, adjusted, and recorded maintenance data periodically by LONGJIA Authorized Dealer to maintain the motorcycle at the optimum condition The above maintenance schedule is established by taking the monthly 1000 kilometers as a reference which ever comes first.

  • Page 13: Lubrication System

    2 MAINTENANCE INFORMATION LUBRICATION SYSTEM Engine Oil Capacity Remove dipstick to check the oil level. If oil level is below the lower limit mark, add oil to the specified upper limit mark. Oil change Shut off the engine and remove dipstick. Remove the oil drain plug on the bottom-left of crankcase to drain oil.

  • Page 14: Gear Oil

    2 MAINTENANCE INFORMATION GEAR OIL Inspection Check gear oil if leaking. Park the motorcycle with main stand on flat level place. Remove the oil drain plug and drain gear oil into a measurement cup. Check gear oil if enough. Replacement At first, remove the gear oil refilling bolt, and then remove the draining plug.

  • Page 15: Air Cleaner

    2 MAINTENANCE INFORMATION AIR CLEANER Remove frame body cover. Remove screws from the air cleaner cover. Remove element of air cleaner. Check the element if dirt or damaged. Replace it with new one if dirt or damaged Caution Do not try to clean the paper filter Install the air clean cover precisely and properly Clean and check the air filter more frequently, if you are riding in wetty and dusty areas.

  • Page 16: Valve Clearance Inspection And Adjustment

    2 MAINTENANCE INFORMATION VALVE CLEARANCE INSPECTION AND ADJUSTMENT Check & adjust valve clearance with feeler gauge. Valve clearance (IN/EX): 0.07-0.12mm. Loosen fixing nut and turn the adjustment nut for adjustment. Caution Make sure that valve-rocker arm is be adjusted to standard value when adjusting it, and re-check the valve clearance after tightened the fixing nut.

  • Page 17: Ignition Timing

    2 MAINTENANCE INFORMATION IGNITION TIMING Caution ECU ignition system is set by manufacturer, so it can not be adjusted. Ignition timing check procedure is for checking whether ECU function is in normal or not. Remove ignition timing hole cap located on the cooling fan cap, or remove the cooling fan cap.

  • Page 18: Cylinder Copmression Pressure

    2 MAINTENANCE INFORMATION CYLINDER COPMRESSION PRESSURE Warn up engine and then turn off the engine. Remove the luggage box and the center Cover. Remove spark plug cap and spark plug. Install compression gauge. Full open the throttle valve, and rotate the engine by means of electric stand motor.

  • Page 19: Lubrication System

    3 LUBRICATION SYSTEM IMPORTANT INFORMATION ................. 3-2 ENGINE OIL ....................3-3 CLEANING ENGINE OIL STRAINER ............3-3 OIL PUMP REMOVAL ..................3-4 OIL PUMP INSPECTION ................3-5 OIL PUMP RE-ASSEMBLY ................3-5 OIL PUMP INSTALLATION ................3-6 GEAR OIL ...................... 3-7...

  • Page 20: Important Information

    3 LUBRICATION SYSTEM IMPORTANT INFORMATION General Information This chapter contains maintenance operations for the engine oil pump, engine oil and gear oil. Specifications Engine oil capacity：overhauI：950cc change：800cc Oil viscosity：15W-40 or equivalent Gear Oil：overhauI：150cc change：100cc Oil viscosity of gear oil：SAE 80W-90 Items Standard Limit...

  • Page 21: Engine Oil

    3 LUBRICATION SYSTEM ENGINE OIL Turn off engine, and park the vehicle in level ground with main stand. Check oil level with oil dipstick after 3-5 minutes. Do not rotate the dipstick into engine as checking. If oil level is nearly low level, fill out recommended oil to upper level.

  • Page 22: Oil Pump Removal

    3 LUBRICATION SYSTEM OIL PUMP REMOVAL Remove the alternator Remove the engine right cover Remove the one-way clutch and starting gear Make sure that the pump axle can be rotated freely Remove the oil pump cover (2 bolts), and then the oil pump driving gear nut and the gear and oil pump driver chain.

  • Page 23: Oil Pump Inspection

    3 LUBRICATION SYSTEM OIL PUMP INSPECTION Check the clearance between oil pump body and outer rotor. Limit: below 0.12 mm Check clearance between inner and outer rotors. Limit: below 0.12 mm Check clearance between rotor side face and pump body. Limit: below 0.2 mm OIL PUMP RE-ASSEMBLY Install inner and outer rotors into the pump body.

  • Page 24: Oil Pump Installation

    3 LUBRICATION SYSTEM Install drive gear and clamp. Caution Confirm whether the oil pump can rotate smoothly. OIL PUMP INSTALLATION Install the oil pump Install oil pump outer cover Install the starting gear and the alternator...

  • Page 25: Gear Oil

    3 LUBRICATION SYSTEM GEAR OIL Park the vehicle on level ground with main stand. Turn off engine and remove both engine oil filling bolt and oil draining bolt. Remove gear oil filling hole bolt and place a measurement cup under the draining plug. Remove the oil draining plug and the pour gear oil into the measurement cup.

  • Page 26: Fuel System

    4 FUEL SYSTEM TROUBLESHOOTING ................... 4-1 AIR CLEANER ....................4-2 INTAKE-TUBE AND THROTTLE BODY ............4-3 TROUBLESHOOTING Poor engine start Stall after started •No fuel in fuel tank •Malfunction of automatic by-starter •Clogged fuel tube •Incorrect ignition timing •Too much fuel in cylinder •Malfunction of ECU •No spark from spark plug •Dirty engine oil...
  • Page 27 4 FUEL SYSTEM AIR CLEANER Remove frame body cover. Remove screws from the air cleaner cover. Remove element of air cleaner. Install the air cleaner in the reverse order of removal. Remove the air cleaner element (2 screws). With compressed air to clean dirty around the element. Replace it if it is too dirty to clean Caution The air cleaner element is made of paper so...
  • Page 28 4 FUEL SYSTEM INTAKE-TUBE AND THROTTLE BODY Remove frame body cover. Remove screws from the Intake-tube. Remove element of throttle body. Install the air cleaner in the reverse order of removal. Remove oil injector Remove the bolt from Intake-tube Remove the cover of oil in injector Remove the oil injector Replace it if damaged .

  • Page 29: Removal Of Engine

    5 REMOVAL OF ENGINE IMPORTANT INFORMATION ................. 5-1 REMOVE OF ENGINE ................... 5-2 REMOVAL OF ENGINE HANGED BUSHING ..........5-5 INSTALLATION OF ENGINE ................. 5-6 IMPORTANT INFORMATION General Information • Engine must be supported by a suitable tool in while removing engine from the vehicle. •...
  • Page 30 5 REMOVAL OF ENGINE REMOVAL OF ENGINE Remove the body cover . Remove the power connector of auto by- start. Remove the generator wire and pulse generator connector. Remove the starter motor wire on the starter magnetic switch. Remove the spark plug.
  • Page 31 5 REMOVAL OF ENGINE Loose the strap screw of the air cleaner guide, and then the air cleaner guide Remove the exhaust muffler Remove the rear wheel Remove the air cleaner fasten bolts...
  • Page 32 5 REMOVAL OF ENGINE Remove the rear shock absorber bottom bolt Remove the engine hanger nut and bolt (engine side), and then remove the engine Caution Support the engine with tooling to prevent from damage by falling down as removing the engine. Check any damage for the engine hanger bush , rear shock absorber bushing, and cushion rubber bush for damage.

  • Page 33: Removal Of Engine Hanger Bush

    5 REMOVAL OF ENGINE REMOVAL OF ENGINE HANGER BUSH If engine hanger bush and the cushion rubber of rear shock absorber bush damaged. Then, with the bushing remover /presser, Φ28mm &Φ20mm, to press the bushing out, and replace it with new one. Engine hanger bush: Φ28mm Rear shock absorber bushing: Φ20mm Pressing out...

  • Page 34: Installation Of Engine

    5 REMOVAL OF ENGINE INSTALLATION OF ENGINE Check and replace engine hanger bush and shock absorbed bush if damaged. Install the engine according to the reversing order of removal. Caution Notice both feet and hands safety for squeezing as engine installation. Do not bent or squeeze each wires or hose.
  • Page 35 6 CYLINDER HEAD / VALVE IMPORTANT INFORMATION ................. 6-2 TROUBLESHOOTING ................... 6-3 CAMSHAFT REMOVAL ................. 6-4 CAMSHAFT INSPECTION ................6-5 MEASURE THE VALVE ROCKER ARM I.D........... 6-5 VALVE GUIDE ....................6-7 VALVE SEAT INSPECTION AND SERVICE ..........6-8 CYLINDER HEAD INSTALLATION ..............6-9 CAMSHAFT INSTALLATION .................

  • Page 36: Cylinder Head / Valve

    6 CYLINDER HEAD / VALVE IMPORTANT INFORMATION General Information  This chapter contains maintenance and service information for cylinder head, valve, and camshaft as well as valve rocker arm.  Cylinder head service cannot be carried out when engine is installed in vehicle. Specification Unit（mm）...

  • Page 37: Troubleshooting

    6 CYLINDER HEAD / VALVE TROUBLESHOOTING Engine performance will be effected by troubles on engine top end. The troubles usually can be determinate or by performing cylinder compression test and judging the abnormal noise generated 1. Rough Idle Low compression pressure. Standard：12±...

  • Page 38: Camshaft Removal

    6 CYLINDER HEAD / VALVE CAMSHAFT REMOVAL Remove the bolts and then remove the cylinder head cover . Loosen the screw of camshaft chain adjuster and remove O-ring. With a flat screwdriver to tighten the screw of camshaft chain adjuster in a clockwise direction motion for release adjuster.

  • Page 39: Camshaft Inspection

    6 CYLINDER HEAD / VALVE CAMSHAFT INSPECTION Inspect cam lobe height for damage Service Limit IN: Repalce when less than 31.720mm EX: Replace when less than 31.390mm Inspect the camshaft bearing for looseness or worn out. If any, replace whole set of camshaft and bearing. MEASURE THE VALVE ROCKER ARM I.D.

  • Page 40: Cylinder Head Disassembly

    6 CYLINDER HEAD / VALVE Remove the 2 cylinder head mounting bolts from cylinder head left side cover. Remove cylinder head gasket and 2 dowel pins. Remove cam chain guide. Clean up residues from the matching surfaces of cylinder and cylinder head. Caution Do not damage the matching surfaces of cylinder and cylinder head.

  • Page 41: Cylinder Head Inspection

    6 CYLINDER HEAD / VALVE CYLINDER HEAD INSPECTION Check if spark plug and valve holes are crack. Measure cylinder head flatness with a straightedge and flat feeler gauge. Service limit: 0.5mm Valve spring free length Measure the free length of intake and exhaust valve springs.

  • Page 42: Valve Seat Inspection And Service

    6 CYLINDER HEAD / VALVE VALVE SEAT INSPECTION AND SERVICE Clean up all carbon deposits onto intake and exhaust valves. Clean up the emery after grimding and do not let emery enter into between valve stem and valve guide. Lubricate valve stem with engine oil, and then insert the valve into valve guide.

  • Page 43: Cylinder Head Installation

    6 CYLINDER HEAD / VALVE CYLINDER HEAD INSTALLATION Install the lock pins and new cylinder head gasket onto the cylinder head. Install the cam chain guide. Install the cylinder head CAMSHAFT INSTALLATION Install intake/exhaus valve rocker arm and rocker arm shaft Caution The tangent of rocker shaft of intake valve...

  • Page 44: Install The Lock Pins

    6 CYLINDER HEAD / VALVE INSTALL THE LOCK PINS. Install the camshaft holder, gasket and nut onto the cylinder head. Torque value: 18-22 N.m Install the spark plug and tighten it. Torque value: 10-14 N.m Caution Apply with oil onto the thread of cylinder head bolts and tighten the bolts in diagonally for times.
  • Page 45 7 CYLINDER / PISTON IMPORTANT INFORMATION ................. 7-2 CYLINDER REMOVAL ................... 7-3 PISTON REMOVAL ..................7-5 PISTON RING INSTALLATION ..............7-7 PISTON INSTALLATION ................7-8 CYLINDER INSTALLATION ................7-8...

  • Page 46: Cylinder / Piston

    7 CYLINDER / PISTON IMPORTANT INFORMATION General Information Both cylinder and piston service cannot be carried out when engine mounted on frame SPECIFICATION Item Standard Limit 52.390-52.410 52.500 — Flatness 0.050 Cylinder — Roughness 0.050 — Cylindrical 0.050 Top ring 0.015-0.050 0.090 Clearance between piston rings...

  • Page 47: Cylinder Removal

    7 CYLINDER / PISTON CYLINDER REMOVAL Remove cylinder head. (refer to chapter 6) Remove bolts and then take out the cam chain auto-adjuster. Remove cam chain plate. Remove cylinder. Remove cylinder gasket and dowel pins Clean the residues attached onto the matching surfaces of cylinder and crankcase.
  • Page 48 7 CYLINDER / PISTON Cover the holes of crankcase and cam chain with a piece of cleaning cloth. Clean up all residues or foreign materials from the two matching surfaces of cylinder and crankcase. Caution To soak the residues into solvent so that the residues can be removed more easily INSPECTION Check if the inner diameter of cylinder is worn out or...

  • Page 49: Piston Removal

    7 CYLINDER / PISTON PISTON REMOVAL Plug crankcase opening with a cleaning cloth to prevent from piston pin snap ring or other parts falling into crankcase when disassembling. Hold another snap ring with pliers. Push out the piston pin from the side that not removed the snap ring.
  • Page 50 7 CYLINDER / PISTON Measure the outer diameter of piston pin. Service Limit: 14.96mm Measure the inner diameter of connecting rod small end. Service Limit: 15.06mm Measure the inner diameter of piston pin hole. Service Limit: 15.04mm Calculate clearance between piston pin and its hole. Service Limit: 0.02mm Measure piston outer diameter.

  • Page 51: Piston Ring Installation

    7 CYLINDER / PISTON PISTON RING INSTALLATION Clean up piston top, ring groove, and piston shirt. Install the piston ring onto piston carefully. Place the openings of piston ring as diagram shown Caution Do not damage piston and piston rings as installation. All marks on the piston rings must be forwarded to up side.

  • Page 52: Piston Installation

    7 CYLINDER / PISTON PISTON INSTALLATION Install piston and piston pin, and place the IN mark on the piston top side forward to intake valve. Install new piston pin snap ring. Caution Do not let the opening of piston pin snap ring align with the opening piston ring.
  • Page 53 8 V-BELT DRIVING SYSTEM/KICK STARTER ARM IMPORTANT INFORMATION ................. 8-2 KICK STARTER ARM ..................8-3 LEFT COVER FILTER ..................8-3 DRIVE BELT ....................8-4 DRIVEN PULLEY INSTALLATION ..............8-5 DRIVE PULLEY ..................... 8-6 DRIVE PULLEY INSPECTION ............... 8-7 DRIVE PULLEY ASSEMBLY / INSTALLATION ..........8-7...

  • Page 54: Important Information

    8 V-BELT DRIVING SYSTEM/KICK STARTER ARM IMPORTANT INFORMATION GENERAL INFORMATION Drive face, clutch, and driven pulley can be serviced on the motorcycle. Drive belt and drive face surface must be free of grease Specificaion Unit：mm Item Standard Limit Drive belt width 19.500 18.00 ID of movable drive face bushing...

  • Page 55: Kick Starter Arm

    8 V-BELT DRIVING SYSTEM/KICK STARTER ARM KICK STARTER ARM kick shaft assy Disassembly Remove the return spring plate (1 bolt), and remove return spring, starter shaft. Remove driving gear, friction spring and washer. spring,torsion kick pinion assy Inspection Check if starter shaft, driving gear, socket and bearing hole for wear or damage.

  • Page 56: Drive Belt

    8 V-BELT DRIVING SYSTEM/KICK STARTER ARM DRIVE BELT Removal Remove left crankcase cover. Hold the drive face with a universal fixture, and then remove the nut and drive face. Hold drive face with universal fixture, and remove nut and clutch outer. Caution Using special service tools for tightening or flange nut...

  • Page 57: Driven Pulley Installation

    8 V-BELT DRIVING SYSTEM/KICK STARTER ARM DRIVEN PULLEY INSTALLATION Pull out the driven face and then insert the Movable drive belt into movable driven pulley. driven face Caution Pull out the driven face and then insert the drive belt into movable driven pulley so that the drive belt can be installed onto movable driven pulley more easily.

  • Page 58: Drive Pulley

    8 V-BELT DRIVING SYSTEM/KICK STARTER ARM DRIVE PULLEY Remove left crankcase cover. Hold drive face with universal fixture, and then remove drive face nut. Remove drive face. Movable drive face Remove the drive belt from the pulley. Remove movable drive face set and drive face boss from crankshaft.

  • Page 59: Drive Pulley Inspection

    8 V-BELT DRIVING SYSTEM/KICK STARTER ARM DRIVE PULLEY INSPECTION The movable drive face is moved axially by means of centrifugal force created by weight rollers adapting to ramp plate under various speed and load conditions. Thus, if weight rollers are worn out or damaged, the centrifugal force will be effected.
  • Page 60 8 V-BELT DRIVING SYSTEM/KICK STARTER ARM Apply with grease 4~5 g to inside of movable drive face hole, and install drive face boss. Caution The surface of movable drive face and drive face has to be free of grease. Clean it with cleaning solvent.

  • Page 61: Transmission Gear Box

    9 TRANSMISSION GEAR BOX IMPRORTANT INFORMATION ..............9-2 DISASSEMBLY OF TRANSMISSION GEAR BOX ........9-3 INSPECTION OF TRANSMISSION GEAR BOX ..........9-3 BEARING REPLACEMENT ................9-4 RE-ASSEMBLY OF TRANSMISSION GEAR BOX ........9-6 10-14 N.m 10-14 N.m...

  • Page 62: Imprortant Information

    9 TRANSMISSION GEAR BOX IMPRORTANT INFORMATION Torque value •Application gear oil: 4-stroke lubricant •Gear box cover bolts: 20-24 N.m •Gear oil drain plug bolt: 10-14 N.m •Oil quantity:150cc（100cc when change） 。 •Gear oil filling bolt: 10-14 N.m SPECIAL SERVICE TOOLS •Inner type bearing puller •Outer type bearing puller •Gear box oil seal installer...

  • Page 63: Disassembly Of Transmission Gear Box

    9 TRANSMISSION GEAR BOX DISASSEMBLY OF TRANSMISSION GEAR BOX Remove the rear wheel. (refer to chapter 15) Remove the clutch. Drain gear oil out from gear box. Remove gear box cover bolts (7 bolts) and then remove the cover and the final drive shaft. Remove gasket and setting pin.

  • Page 64: Bearing Replacement

    9 TRANSMISSION GEAR BOX Rotate each bearing’s inner ring with fingers. Check if bearings can be turned smoothly and silently, and also check if bearing outer ring is mounted on gear box & cover tightly. If bearing rotation is uneven, noising, or loose bearing mounted, then replace it.
  • Page 65 9 TRANSMISSION GEAR BOX Remove oil seal from the gear box. Remove the drive shaft bearing from the gear box cover with the inner type bearing Caution Using the bearing protector as pressing out the drive shaft from the gear box cover. Specified tool: Inner type bearing puller.

  • Page 66: Re-Assembly Of Transmission Gear Box

    9 TRANSMISSION GEAR BOX RE-ASSEMBLY OF TRANSMISSION GEAR BOX Install final drive shaft and final drive gear， countershaft and counter shaft gear. Install the setting pins(2 pins) and new gasket Apply with grease onto the oil seal lip of final drive shaft.

  • Page 67: 10 A.c. Generator / Starting Clutch

    10 A.C. GENERATOR / STARTING CLUTCH IMPORTANT INFORMATION ............... 10-1 A.C.GENERATOR REMOVAL ..............10-2 FLYWHEELS DISASSEMBLE ..............10-2 REMOVE A.C. GENERATOR STATOR ............10-3 RIGHT CRANKCASE COVER REMOVAL ........... 10-3 ONE-WAY CLUTCH DISASSEMBLY ............10-5 INATALL A.C. GENERATOR STATOR ............10-7 INSTALL THE COOLING FAN ..............

  • Page 68: A.c.generator Removal

    10 A.C. GENERATOR / STARTING CLUTCH A.C.GENERATOR REMOVAL FLYWHEELS DISASSEMBLE Drain out the engine oil. Remove the exhaust muffler. Remove the fan shroud. Remove the fan. Hold the flywheel with the universal fixture. Remove the 10mm nut on the flywheel. Special Service Tools: Universal Fixture 10-2...

  • Page 69: Remove A.c. Generator Stator

    10 A.C. GENERATOR / STARTING CLUTCH Remove the flywheel with the flywheel puller. Special service tools: Flywheel puller Shaft protector Caution Install a shaft protector on the right end of crankshaft to avoid damaging the crankshaft before installing the flywheel puller.

  • Page 70: Starting Clutch

    10 A.C. GENERATOR / STARTING CLUTCH STARTING CLUTCH Starting Clutch Removal Hold the starting driven gear with the universal fixture. Remove the 22mm anti-loosen lock nut and gasket. Special service tools: Anti-loosen lock nut socket Universal fixture Caution The mounting nut is left-turn thread. Remove the starting driven gear.

  • Page 71: One-Way Clutch Disassembly

    10 A.C. GENERATOR / STARTING CLUTCH Check the starting driven gear for wear or damage. Measure the ID of the starting driven gear. Service Limit:ID: 32.06 mm or less Check the starting reduction gear and shaft for wear or damage. Measure the ID of the starting reduction gear.
  • Page 72 10 A.C. GENERATOR / STARTING CLUTCH Installation Install the components in the reverse procedures of removal. Caution Add adhesive onto the thread of hex socket bolt. Torque value：10-14 N.m Install reduction gear shaft and reduction gear. Install starting clutch. Install the starting driven gear onto the starting clutch.

  • Page 73: Inatall A.c. Generator Stator

    10 A.C. GENERATOR / STARTING CLUTCH Install dowel pins and new gasket on the crankcase. Replace the right crankshaft oil seal of the crankcase and apply some oil onto the oil seal lip. Install right crankcase cover onto the right crankcase.

  • Page 74: Install The Cooling Fan

    10 A.C. GENERATOR / STARTING CLUTCH INSTALL THE COOLING FAN Install the cooling fan shroud. Install the exhaust muffler. Add enough engine oil according to the standard (Value 800cc) 10-8...

  • Page 75: Crnkcase & Crankshaft

    11 CRANKCASE / CRANKSHAFT IMPORTANT INFORMATION ............... 11-2 DISASSEMBLY OF CRANKCASE ............... 11-3 SPECIAL SERVICE TOOLS: ............... 11-3 8-12 N.m 7-10 N.m 35-45 N.m 8-12 N.m 11-1...

  • Page 76: Specification

    11 CRANKCASE / CRANKSHAFT IMPORTANT INFORMATION General Information This Section describes disassembly of the crankcase so that the crankshaft can be serviced. Chang the crankshaft comp if bearing or timing sprocket damage. SPECIFICATION : Unit：mm Item Standard Limit Left, right clearance of the big end of the connecting rod 0.100-0.300 0.550 Radial clearance of the big end of the connecting rod...

  • Page 77: Disassembly Of Crankcase

    11 CRANKCASE / CRANKSHAFT DISASSEMBLY OF CRANKCASE Remove the 2 bolts from the right side of crankcase. Remove the cam chain tensioner (hex socket bolt) from the left side of crankcase. Place the left side of crankcase upward, and then install the crankcase remover/set onto the crankcase.
  • Page 78 11 CRANKCASE / CRANKSHAFT Remove the crankshaft from the right crankcase. Caution The bearing is press fit into left and right crankshaft . Remove gasket and dowel pins. Scrape gasket residues off the crankcase surface. Caution damage joint surface crankcase. Soak the gasket residues into solvent and the residues will be removed easily.
  • Page 79 11 CRANKCASE / CRANKSHAFT Measure left and right side clearance of connecting rod big end. Service limit: Replace when it is more than 0.55 mm Measure the radial clearance of the big end at the vertical directions. Service limit:0.05 mm Place the crankshaft onto a V-block and measure run-out of the crankshaft with dial gauge.
  • Page 80 11 CRANKCASE / CRANKSHAFT Install cam chain into the chain hole of the left crankcase, and then split out the cam chain. Caution Do not damage the cam chain as installing the crankshaft. Install crankshaft into the left crankcase and then install two dowel pins and new crankcase gasket.
  • Page 81 11 CRANKCASE / CRANKSHAFT Apply with some grease onto the oil seal lip and then install it onto the left crankcase. Press-fit the oil seal to specified position with the oil seal installer (25x40x8). Special service tools: the oil seal installer (25x40x8) 11-7...

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