Lifan LF125-26C. Service manual (2024)

FOREWORD

This manual covers the structure, operation, inspection, maintenance and repair of LF125-26C(Euro V) for use by the LIFAN dealers and qualified mechanics.

With both the descriptions and figures/drawings, you may have a comprehensive understanding of the structure as well as service and repair skill.

Lifan 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. LIFAN reserves the right to make changes at any time without notice and without incurring any obligation.

No part of this publication may be reproduced without written permission.

LIFAN TECHNOLOGY (GROUP) CO., LTD.

Jan, 2024

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

CHAPTER 1 GENERAL

1.1 Vehicle Introduction

LF125-26C (Euro V) two-wheeled motorcycle, with beautiful and novel appearance, compact structure, bright colors, and smooth lines, brings people a strong visual

impact. 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. In addition, the

vehicle is equipped with front and rear disc brakes and hydraulic spring damping shock absorbers, which maximizes the user's riding safety, comfort, and other needs.

①

②

③

④

⑥

⑦

⑧

⑤

④

③ ②

①

⑧

⑦

⑥

⑤

①Front wheel ②Rear brake pedal ③Front footrest ④Exhaust muffler

①Front fender ②Headlight ③Steering bar ④Fuel tank ⑤Rear fender

⑤Rear wheel ⑥Handrail ⑦VIN ⑧Seat

⑥Taillight ⑦Rear footrest ⑧Front hydraulic brake

1-1

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×55.5mm

Displacement

124.7 cm³

Compression ratio

10.5:1

Engine

Air cleaner

Plastic housing with paper element

Lubrication

Press/splash

Starting mode

Electric/kick start

Max. net power

6.7kW/8000r/min

Max. torque

9.0N·m/6000r/min

Idle speed

1500±100 r/min

Front shock absorber

Hydraulic telescopic damping type

Rear shock absorber

Hydraulic telescopic damping type

Steering bar angle

≤42°

Driving system

Front

2.50-17-4PR/200kPa

Tyre size/pressure

Rear

2.75-17-4PR/225kPa

Drive mode

Chain

Turning circle diameter

4060mm

1-2

Clutch

Wet, multi-plate type

Transmission

4-speed, constant mesh

Primary reduction

4.059

Final reduction

2.571

1st

2.833

Drive Train

2nd

1.706

Gear ratio

3rd

1.238

4th

0.958

Drive chain

Model

08MB

Link No.

106

Front

disc brake

Braking system

Rear

disc brake

Ignition

ECU

Ignition advance angle

0-40°

Spark plug

CPR8EA

Spark plug gap

0.8-0.9mm

Battery

12V6Ah

Fuse

15A

Electrical system

Headlight

HS1/12V35W

Front position light

LED

Tail/brake light

LED

Winker

LED

Turn signal indicator

LED

High beam indicator

LED

Gearshift indicator

LED

1-3

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

Tightening torque: 6~10N

TIGHTENING BOLT M5

BOLT M6

4) Unscrew the valve cover bolt M6 to remove the cover.

2) Unscrew the cylinder head connecting bolt M6.

Tightening torque: 8~12N

BOLT M6

CONNECTING BOLT M6

2-1

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

DOWEL PIN

2) Remove the guide pulley pin M6 and guide pulley.

4) Remove the connecting bolt M6 of cylinder block.

Tightening torque: 8~12N

GUIDE PULLEY PIN

CONNECTING BOLT

2-10

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. Engine lacks power, has unstable idle speed.

replace the cylinder head

Cylinder Block

Large gap of cylinder block and piston, cylinder block and piston

Seriously wear of cylinder

rings. Engine fails or is hard to start. Engine lacks power, has

Repair by a cylinder boring machine or

block

unstable idle speed. Blue or white smoke comes from the exhaust

replace with a new cylinder

pipe.

Broken cylinder block gasket

Oil leaks between cylinder block and crankcase.

Replace the gasket

2-13

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 SEAT

VALVE

SPRING SEAT

2) Remove and check the valve clip, valve spring upper seat for wear, repair or

4) Remove and check the oil shield for wear and damage, replace it if necessary.

replace them if necessary.

2-16

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).

Exhaust valve

Intake valve

6) Measure the diameter of valve stem, replace the valve stem if it is beyond the

service limit (intake valve＜Φ4.950mm, exhaust valve＜Φ4.950mm).

8) Measure the free length of valve spring, replace it if it is beyond the service

limit (＜27.7mm).

NOTE: The dense coils face upward when installing the spring.

2-17

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

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.

of the service limit (intake cam＜32.15mm, exhaust cam＜31.94mm).

Counterclockwise rotate the magneto rotor until “T” mark on it aligns with the

sign of left crankcase cover, while both the intake and exhaust valves are closed.

Tightening torque: 8~12N

VIEW-HOLE PLUG

2-18

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

Tightening torque: 40~50N

14) Unscrew the bolt to remove the left crankcase cover.

Tightening torque: 8~12N

16) Unscrew the plate cover bolt to remove the starting chain, tensioning plate,

guide plate and starting clutch sprocket weldment, and then remove the plate

cover and seal ring. Tightening torque: 8~12N

2-19

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

Timing chain is elongated and running with knocking sound

Replace the timing chain

Working surface is scratched or

Abnormal sound from rocker arm, engine lacks power

Replace the rocker arm

seriously worn

Rocker Arm

Rocker arm hole is worn

Abnormal sound from rocker arm, engine lacks power

Replace the rocker arm

Rocker arm shaft is worn

Abnormal sound from rocker arm, engine lacks power

Replace the rocker arm shaft

Engine fails or is hard to start. Engine lacks power and has unstable idle

Adjust the valve clearance to

Little valve clearance

speed.

0.03~0.06mm

Adjust the valve clearance to

Large valve clearance

Knocking sound

0.03~0.06mm

Too much carbon deposits on the

Engine fails or is hard to start. Engine lacks power and has unstable idle

Clear away carbon deposits

Valve

surface

speed.

and grind the valve

Working surface is seriously worn or

Engine fails or is hard to start. Engine lacks power and has unstable idle

Clear away carbon deposits

has pits

speed.

and grind the valve

Valve stem is seriously worn

Thick blue smoke from exhaust pipe

Replace the valve

Valve stem is deformed

Engine fails to start.

Replace the valve

Valve Spring

Spring is broken

Engine fails or is hard to start. Noises from cylinder head

Replace the valve spring

2-21

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

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. Check

cover with a rubber hammer to remove it. Tightening torque: 8~12N

the clutch separating rod for wear, replace it if necessary.

CLUTCH SEPARATING ROD

TIGHTENING BOLT

2-26

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

sprocket, unscrew the bolt to remove the plate cover and seal ring.

Tightening torque: 8~12N

TENSIONING PLATE

STARTING CHAIN

MAGNETO ROTOR

GUIDE PLATE

STARTING

CLUTCH

SPROCKET

NUT

PLATE

SCREW

COVER

10) Unscrew the bolt to remove the sprocket locating plate.

Tightening torque: 8~12N

12) Check the left oil seal of crankshaft and oil seal of starting clutch sprocket

for wear, replace them if necessary.

BOLT

SPROCKET

LEFT OIL SEAL

OIL SEAL

SPROCKET

LOCATING PLATE

2-28

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

unstable idle speed.

crankcase

Engine fails or is hard to start. Engine lacks power and has

Broken cylinder bolt

Replace the cylinder bolt

unstable idle speed.

Damaged oil seal

Oil leaks from oil seal.

Replace the oil seal

Right crankcase cover is damaged or

Repair or replace the right crankcase

Right Crankcase

Oil leaks from right crankcase cover.

cracked

cover

Cover

Damaged gasket

Oil leaks between right crankcase cover and crankcase.

Replace the gasket

Left Crankcase

Left crankcase cover is damaged or

Repair or replace the left crankcase

Oil leaks from left crankcase cover.

Cover

cracked

cover

Plate Cover

Broken seal ring

Oil leaks from left crankcase cover.

Replace the seal ring

2-31

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

Tensioning Rod

Tensioning rod OD

Φ11.985～Φ12

Φ11.975

beyond the limit

value

Length of starting chain

(62 links when

Replace when

387.35~387.92

Starting Chain

determining with 80N

388.92

beyond the limit

(62 links after stretch)

Determine with 80N force

force)

value

Length of timing chain (90

Replace when

links when determining

527.4～527.84

Timing Chain

529

beyond the limit

with 80N force)

(90 links after stretch)

Determine with 80N force

value

2-32

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

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. Replace them if

necessary.

CLUTCH BEARING

GASKET

CLUTCH COVER PLATE

2-34

9) Remove the tightening bolt (M6) from the oil box.

11) Remove the snap ring of auto clutch main body.

(Tightening torque: 8-12N

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.

replace the nut if necessary. (Locknut: M14×1, tightening torque: 45-55N

SNAP RING

LOCKNUT OF

CLUTCH MAIN

BODY

LOCKNUT OF AUTO

CLUTCH MAIN BODY

2-35

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

CLUTCH

DAMPING

SLEEVE

CLUTCH SPRING

SNAP RING

AUTO CLUTCH

COVER PLATE

AUTO CLUTCH

DISC SPRING

14) Check the gear for damage or missing teeth, and replace it if necessary.

16) Check the clutch end cover for damage, and replace it if necessary. And

replace the spring if it is inelastic.

CLUTCH END COVER

SPRING

2-36

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 & 1.4mm).

CLUTCH PRESSING DISC

18) Remove and check the clutch pressing plate for wear. Measure the

20) Check the primary driven gear for wear, and replace it if necessary.

deformation flatness with a feeler gauge, and replace the pressing plate if it

exceeds the service limit 0.2mm.

CLUTCH PRESSING

PLATE

2-37

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 &

The contact face is excessively worn.

Clutch is slipping.

Replace

pressing plate

Excessively worn

Clutch is slipping, not disengaged thoroughly.

(thickness＜2.8/1.4mm)

Clutch drive/driven plate

Replace the drive/driven plate as a set.

Severely deformed

Clutch is slipping.

Clutch spring

Inelastic or broken

Do.

Replace the spring.

2-38

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. (Tightening torque: 8-12N

(Tightening torque: 8-12N

GEAR LOCATING PLATE

SPRING

2) Remove and check the gearshift shaft for wear, and replace it if necessary.

4) Check the gear indicator contact for wear, and replace it if necessary.

2-39

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

MAIN SHAFT

GEARSHIFT CAM

COUNTERSHAFT

8) Remove the fork from the gearshift cam, check it for wear, and replace it if

6) Remove the crank connecting rod comp.

its claw thickness exceeds the service limit (3.8mm).

CRANK CONNECTING ROD

MAIN SHAFT

COUNTERSHAFT

FORK

GEARSHIFT CAM

2-40

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

12) Remove and check the 4th gear of countershaft for wear.

gap is excessively large.

COUNTERSHAFT

COUNTERSHAFT 4TH GEAR

MAIN SHAFT

2-41

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.

Do.

Gear

arc shape.

Gear meshing hole is worn into trumpet shape.

Do.

Fork groove is excessively worn.

Do.

Fork claw is excessively worn.

Do.

Replace the fork.

Fork

Fork is deformed.

It's difficult to gearshift.

Do.

Fork hole is excessively worn.

Do.

Gearshift cam

Gearshift groove is excessively worn.

Do.

Replace the gearshift cam.

Excessive wear or damage

Do.

Replace the gear locating plate.

Gear locating

plate

Spring is inelastic or broken.

It's easy to disengage.

Replace the torsion spring of locating plate.

Spline is damaged.

It fails to gearshift.

Replace the gearshift shaft.

Gearshift shaft is deformed.

It's difficult to gearshift.

Do.

Gearshift shaft

Gearshift shaft is worn or broken.

Do.

Return spring is inelastic or broken.

It's difficult to gearshift, or pedal fails to return.

Replace the return spring.

Oil seal

Oil seal is severely worn, damaged or aged.

Oil leaks.

Replace the oil seal.

2-45

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. and gearshift cam are shown as the following figure.

micrometer gauge. Replace it with a new one , if it exceeds the service limit

(axial: 0.48 mm, radial: 0.05 mm).

MAIN SHAFT COMP.

CRANK CONNECTIND ROD

COUNTERSHAFT COMP.

GEARSHIFT CAM

2-50

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. Replace them if necessary.

LEFT BEARING

RIGHT BEARING

8) Remove the piston rings from the piston. Parallel push each piston ring into

6) Measure the O.D. of the piston pin with a micrometer. Replace it with a new

the cylinder block and check them for wear and elasticity. Measure the opening

one, if it exceeds the service limit (Φ12.78mm).

clearance of each ring with thickness gauge and replace all the piston rings as a

set if they exceed the service limit (Piston ring I&II: 0.7mm, Oil ring: 1.9mm).

2-51

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

Do.

groove

exhaust pipe.

Piston

Scratches on the surface of piston skirt

Do.

Replace the piston.

Piston is excessively worn.

Do.

Piston ring groove is excessively worn .

Thick blue smoke exhausts from the exhaust pipe.

Do.

Piston pin hole is excessively worn.

Knocking sound from piston pin and cylinder

Do.

Crankshaft Pin

Excessively worn

Knocking sound from big-end bearing

Replace the crank connecting rod.

Needle bearing is excessively worn.

Do.

Bearing

Crankshaft bearing is excessively worn

Abnormal noise from crankshaft

Replace the crankshaft bearing.

or damaged.

Engine fails or is hard to start. Engine lacks power

Piston ring is broken

with thick blue smoke exhausting from the

Replace the piston rings as a set.

exhaust pipe.

Piston Ring

Piston ring is excessively worn.

Do.

Engine lacks power with thick blue smoke

Piston ring is inelastic.

Do.

exhausting from the exhaust pipe.

Improper installation

Do.

Reassemble the piston rings.

Piston Pin

Excessively worn

Knocking sound from piston pin

Replace the piston pin.

Small-end hole is excessively worn.

Do.

Replace the connecting rod.

Connecting Rod

Connecting rod is bent.

Knocking sound from cylinder

Do.

Big-end hole is excessively worn.

Knocking sound from big-end bearing

Do.

Sprocket is excessively worn or

Incorrect timing/abnormal noise/engine lacks

Timing Drive Sprocket

Replace the timing drive sprocket.

damaged.

power.

2-53

Piston ring

0.10-0.25

0.5

OPEN GAP (WHEN

Replace if it exceeds the

Close gap

ASSEMBLED)

service limit.

Piston ring

0.25-0.35

0.5

Piston ring set

Piston ring

Approx. 6.2

7.2

Replace if it exceeds the

Open gap

OPEN GAP (NOT

Piston ring

service limit.

Approx.6.6

7.5

ASSEMBLED)

BIG-END BACKLASH

Backlash of

Replace if it exceeds the

connecting rod

0.09-0.36

0.48

service limit.

big-end

Crank

connecting rod

LEFT & RIGHT CRANKSHAFT

RUNOUT

Runout of left

Replace if it exceeds the

and right

0-0.03

0.05

service limit.

crankshaft

2-56

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

2) Check the starting return spring for elasticity. Replace it if it's inelastic.

4) Remove the starting shaft circlip and ratchet spring seat. Replace them if they

are severely worn.

STARTING SHAFT ASSY.

STARTING SHAFT CIRCLIP

2-57

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.

Do.

Starting gear

Replace the gear.

Gear is worn or damaged.

Difficult to start

Ratchet is severely worn.

Slips in starting

Replace the ratchet.

Ratchet

Friction spring of starting gear is broken.

Do.

Replace the spring.

The spline connected with starting lever is

Do.

Replace the starting shaft.

Starting shaft

damaged.

Return spring is broken.

Starting lever fails to return.

Replace the spring .

2-59

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.

GUIDE PLA

TENSION PLATE

STARTING CLUTCH SPROCKET COMP.

8) Check the body, roller and spring of the starting clutch for wear. Replace

6) Check the gearshift indicator. Repair or replace it if necessary.

them if they're severely worn. The roller is required to be able to return freely

and not to be stuck.

STARTING CLUTCH

2-61

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.

Do.

inelastic.

The rotor commutator surface is fouled.

Do.

Starting motor

The rotor commutator surface is burnt or

Do.

damaged.

The rotor commutator surface is excessively

Starting motor lacks power or fails to work.

Do.

worn.

Rotor coil is damaged by short circuit or

Starting motor fails to work.

Do.

broken circuit.

The contact face of starting clutch and roller

Starting clutch slips or has abnormal noise.

Replace the starting clutch gear.

is damaged or excessively worn.

Starting clutch

The contact face of starting clutch and roller

Do.

Replace the starting clutch.

is damaged or worn into groove.

The roller is excessively worn or damaged.

Do.

2-63

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

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. Check the oil

oil. Check the oil passage and clean it if necessary.

passage in the right crankcase cover for foreign matter and clean it if necessary.

OIL

PASSAGE

HOLE

DRAIN PLUG

2-65

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.

Clean the oil passages.

severely damaged.

2.8.3 Reference List of Standard Value and Service Limit Value for Lubrication System

Description

Test Item

Standard Value

Limit Value

Service

Picture

Replace the oil

GAP TUBE

BETWEEN INNER

Gap between inner and

pump if it

AND OUTER

Oil pump inner rotor

0.05-0.08

0.25

ROTORS

outer rotors

exceeds the

service limit.

Replace the oil

GAP BETWEEN

Gap between outer rotor

pump if it

OUTER ROTOR

Oil pump outer rotor

0.10-0.15

0.30

AND OIL PUMP

and oil pump body

exceeds the

BODY

service limit.

2-69

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

14) Remove the valve clip, valve spring and valve stem, check for wear and

16) Ream the valve seats to specified values (Φ25±0.05mm, Φ20.5±0.05mm)

replace them if necessary.

and then grind them.

2-4

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,

Repair threaded hole or replace the cylinder

plug

engine fails or is hard to start.

head

Seriously deformation (＞0.08mm)

Engine fails or is hard to start. Engine lacks power, has

Grind end surface of cylinder head or replace

of cylinder head end surface

unstable idle speed.

the cylinder head

Defects such as pits, erosion etc. are

Cylinder Head

Engine fails or is hard to start. Engine lacks power, has

found on the contact area of valve

Grind valve seats and valves

unstable idle speed.

seats

Valve leaks due to eccentric grinding of valve seats,

Valve guide bore is worn seriously

making the engine difficult to start and unstable at idle

Replace valve guide or cylinder head

(＞5.03mm)

speed.

Engine fails or is hard to start. Engine lacks power, has

Damaged cylinder head gasket

Replace cylinder head gasket

unstable idle speed.

Engine fails or is hard to start. Engine lacks power, has

Loose cylinder head locknut

Tighten up locknut

unstable idle speed.

2-6

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. Engine lacks power, has

Clear away carbon deposits or oil dirt

Spark Plug

around the spark plug

unstable idle speed.

Engine fails or is hard to start. Engine lacks power, has

Replace with a new spark plug in the same

Damaged spark plug insulator

unstable idle speed.

model

Loose spark plug

Engine is hard to start, or has unstable idle speed.

Tighten up the spark plug

2-7

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

frame

Replace the

Deformed or

Effect on parking

center (side)

broken

Center (side)

stand

Center (side) stand

Damaged

Replace the

fails to return.

VIN

return spring

Effect on parking

2) Frame Nameplate

Covering parts

Broken

Effect on appearance

Replace

The frame nameplate is fixed in the rear fork.

Replace the

Fender

Damaged

Effect on fending

fender

Replace the seat

Seat cushion

Broken

Decrease comfort

cushion

Deformed footrest or

Correct or

Deformed or

Footrest

broken footrest

replace the

broken

rubber

footrest rubber

FRAME NAMEPLATE

3-1

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).

REAR BRAKE PEDAL

2) Check the rear-view mirror for looseness, tighten up the mirror and wipe the

4) Check the starting rod for break, repair or replace it if necessary.

mirror surface.

REAR-VIEW MIRROR

STARTING ROD

3-2

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

between steering stem and riser.

Bearing bottom race

The steel ball trail of bottom race is worn

Operation of steering handle is stiff with

out, defects such as pits, dints, cracks are

Replace the bearing bottom race

shaking and vibration.

found.

The steel ball is worn, deformed or

Operation of steering handle is stiff with

Bearing

Replace the bearing as a set

damaged.

shaking and vibration.

Operation of steering handle is stiff with

Steering stem

Deformed

Replace the steering stem

shaking and vibration.

3-9

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

Front fork tube

Oil leaks from the oil seal

Replace the front fork tube

surface

The chromium-plated parts are worn

Oil leaks from the oil seal

Replace the front fork tube

with the substrate exposed.

Bottom case

Broken, deformed or damaged

Oil leaks from the bottom case.

Replace the bottom case

Heavily worn or damaged

The front shock absorber is too soft.

Replace the piston rod

Piston rod

Piston rings are heavily worn or

The front shock absorber is too soft.

Replace the piston rod

damaged

Oil seal

Heavily worn, damaged or aged

Oil leaks from the front shock absorber

Replace the oil seal

Damping oil

Lack of oil

The front shock absorber is too soft.

Fill damping oil as per the specification (60±1ml)

3-13

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.

leakage, replace them if necessary.

REAR SHOCK ABSORBER

2) Unscrew the locknut from the rear shock absorber, check the sleeve boot for

4) Unscrew the locknut from the rear axle, check the rear fork sleeve for wear,

wear, replace it if necessary.

replace the fork if necessary.

3-14

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.

Replace the rear shock absorber

broken.

Deformed

Off-track in running

Correct or replace the rear fork

Rear fork

Cracked

Unable driving

Weld or replace the rear fork

3-15

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).

6) Check the front axle bearing for wear, replace it if necessary.

8) Repeatedly hold and release the front brake lever to test if the front brake

force reaches 200N.

BEARING

3-17

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

Weak braking effect of front hydraulic brake

3.5.1

Rear axle oil seal is worn.

Shortened service life of bearing

Replace the rear axle oil seal

Rear wheel

Surface of brake drum is worn.

Decreased braking force

Replace the rear wheel hub

Brake

Brake shoes are worn.

Decreased braking force

Replace the brake shoes

3-20

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；

element

speed; too much fuel consumption,

water or oil

3. Reinstall the air cleaner element and cover in the

Air cleaner

thick smoke from the exhaust pipe

reverse order of disassembly.

Loud noise from the engine intake

Broken element

Replace the element

system

3-23

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

system

Desoldering and loose

Abnormal sound in the exhaust

Exhaust muffler

Replace the exhaust muffler

internal components

muffler

Decreased engine performance

Carbon deposits in the

Clean off carbon deposits with

raises the combustion gas

exhaust pipe

genuine cleansing solvent

discharge resistance

3-25

4.1

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.

The battery is connected with the generator in parallel, supplying the electric equipment with power together.

● The charging system is designed not only to supply the electrical devices with power when the generator generates sufficient electrical energy, but to charge the

battery. Therefore, a portion of electrical energy is stored to ensure power supply to the electrical devices in case of insufficient power supply caused by low

generator speed or high electrical load.

4.1.1 Removal, Installation and Maintenance of Charging System

Turn on the ignition switch.

IGNITION SW.

Disconnect coupler of the rectifier to main cable and check it for short circuit, broken circuit or poor connection. Repair or replace it if necessary.

RECTIFIER

4-4

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.

COUPLER OF CHARGING/LIGHTING COIL LEAD WIRE (THE YELLOW WIRES

ARE CHARGING/LIGHTING COIL.)

The resistance of charging/lighting coil (at 20℃) should be around 1Ω. Measure the resistance with multimeter, repair or replace the charging/lighting coil if the

value differs considerably from 1Ω.

Check the charging/lighting coil for short circuit, broken circuit or poor connection. Repair or replace it if necessary.

Start the engine, measure the no-load voltage between yellow wires of charging/lighting coil with multimeter (A.C. 200V). The standard value should be as the

following table:

Engine speed (r/min)

2000

3000

4000

5000

6000

7000

8000

No-load voltage of charging/lighting coil (V)

35±1

55±1

70±1

85±1

105±1

120±1

140±1

Replace the magneto stator if the measured no-load voltage differs considerably from the above table.

CHARGING/LIGHTING COIL

4-5

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.

4.1.2 Troubleshooting to Charging System

Description

Damage Form

Trouble Symptom

Remedy

A short circuit occurs to the

Low voltage output or the battery is not fully charged.

Replace the charging/lighting coil

charging/lighting coil.

Magneto

A broken circuit occurs to the

No voltage output, insufficient battery power or the electric

charging/lighting coil. (the resistance is

Do.

appliances are out of work.

∞).

Short/broken circuit occurs or the battery is not fully charged.

Rectifier

The rectifier is faulty.

Light is dim or out of work. The charging current is too high or

Replace the rectifier.

the battery is deformed.

The battery is damaged.

No power output or the starting motor fails to run.

Replace the battery.

Battery

Shortage of electrolyte due to long-term

Low power/voltage output. The starting motor fails to run or

Charge or replace the battery.

storage.

runs slowly. The signal system is out of work.

4-6

4.2

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.

Magneto and exciter coil: the magneto rotor flywheel is of single convex plate with outer trigger type. The standard value of exciter coil (at 20℃) should be in

110Ω-130Ω.

Ignition coil: 1) It is a basic component that converts low-voltage electricity output by the igniter into the required high-voltage electricity, which is actually a step-up

autotransformer (withstand voltage≥35KV). 2) Working principle: When the primary current changes, due to electromagnetic induction, the secondary induction

generates tens of thousands of volts of high-voltage electricity. 3) Composition: It consists of an iron core, a primary coil, a secondary coil, a skeleton, high and low

voltage lead wires, a spark plug cap (including a damping resistor, without a metal shield), etc. The primary coil has a thick enameled copper wire with a smaller

number of turns, while the secondary coil has a thin enameled copper wire with a larger number of turns. In order to prevent high-frequency ignition pulses from

interfering with other radio equipment, a damping resistor of about 5kΩ is added to the spark plug cap of the ignition coil (to weaken or eliminate the high-frequency

oscillations generated by the ignition spark).

Spark plug: 1) Function: introduces the high voltage generated by the ignition coil into the combustion chamber of the engine, forming an electric spark in the gap

between the electrodes to ignite the mixed gas. 2) Structure: consists of a steel shell, ceramic insulator, electrodes, sealing gasket and sealing packing, without

damping resistor; 3) For the model of the spark plug and the standard value of the spark plug gap, please refer to the instruction manual of this vehicle.

4.2.1 Removal, Installation and Maintenance of Ignition System

Turn on the ignition switch.

IGNITION SW.

ELECTRIC STARTER BUTTON

4-7

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. It is strictly prohibited to operate with water on your hands to avoid being shocked by high voltage.

Place the end of the high-voltage wire at the spark plug cap close to the metal positive head of the spark plug, keeping the gap at 5mm to 7mm. Step on the starting

pedal or press the electric starting button, and start the engine to conduct a high-voltage misfire test: If the ignition system is normal, a linear blue-white high-voltage

spark will be generated at this gap. If the spark is red or dark red, it indicates that the ignition high voltage is not high enough (normally 10000V to 20000V

high-voltage pulse). The engine cannot be ignited normally, and the ignition system is faulty. It is also possible to remove the spark plug and connect it to the ignition

coil and high-voltage cap to check the strength of the spark between the electrodes of the spark plug.

For the standard value of spark plug gap, please refer to the instruction manual.

COUPLER OF MAGNETO TO MAIN CABLE

EXCITER COIL

SPARK PLUG

MAGNETO

Check the coupler of magneto to main cable, replace it if necessary.

The Blue/White wire and Green wire in magneto lead wire is exciter coil. Measure the resistance of exciter coil, and the standard value should be in 110Ω-130Ω (at

20℃). Further inspection should be done if the measured value differs. The resistor can be damaged by short circuit, broken circuit, or connecting to the metal shell.

4-8

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).

IGNITION COIL INSERT

OUTPUT HIGH

SPARK PLUG

IGNITION COIL

VOLTAGE CABLE

COUPLER OF ECU TO MAIN

SPARK PLUG CAP

CABLE

Check the ignition coil: The resistance between ignition coil primary insert and iron core is around 0.3-0.8Ω. The resistance between secondary high voltage wire and

iron core is about 4kΩ. The damping resistance of spark plug cap is around 4.5 kΩ-5.5 kΩ. Replace the ignition coil or spark plug cap if necessary.

NOTE: Do not plug or unplug ECU with power on.

It's strictly prohibited to disassemble ECU. Do not pry the pins in socket by hard objects.

Avoid knocking or colliding with hard objects against the ECU. Water/oil penetration into ECU or its connectors are strictly prohibited.

4.2.2 Troubleshooting to Ignition System

Description

Damage Form

Trouble Symptom

Remedy

Ignition power

Broken circuit or poor

No power supply, no/weak ignition spark.

Repair the circuit.

supply

connection

No/weak ignition spark. Engine is hard to start with

Short circuit

Replace the exciter coil.

insufficient power or unstable idle speed.

Exciter coil

Broken circuit (i.e.: the

No ignition spark and the engine fails to start.

Do.

resistance is ∞)

4-9

Ignition

Short circuit

The engine stop switch is out of work.

Replace the faulty switch.

switch/engine stop

switch

Broken circuit

No ignition spark and the engine fails to start.

Do.

ECU

Damaged

Do.

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.

Broken circuit (i.e.: the

Ignition coil

No ignition spark and the engine fails to start.

Do.

resistance is ∞)

Insulator is aged.

Engine is hard to start with insufficient power, unstable idle

Do.

speed or electricity leaks.

Carbon

deposits,

Clean off the carbon deposition, and replace the

electricity leaks or the

spark plug with the same model.

insulator is broken.

Engine is hard to start with insufficient power or unstable idle

Spark plug

Electrodes are worn.

Adjust the spark plug gap or replace spark plug

speed.

with the same model.

Electrodes are burnt.

Replace the spark plug with the same model.

4-10

4.3

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.

IGNITION SW.

DIMMER SW.

TURN SIGNAL SW.

HORN SW.

Check the battery voltage, fuse and charging system according to the method in charging system, and the voltage should be in normal range.

Disconnect the coupler of flashing relay to meter, and check for short circuit, broken

circuit or poor connection. Repair or replace it if necessary.

Check the LED winker for proper function if the flashing frequency or sound is abnormal.

COUPLER OF FLASHING RELAY TO METER

Replace the winker if necessary.

Check the relative couplers for short circuit, broken circuit or poor connection, and replace

them if necessary.

Check the flashing relay and replace it if necessary.

If the rear position light, braking light, meter backlight & indicator lights, horn, front winker, etc., are out of work, please disassemble the meter case, headlight case

and front cowl. Check the relative couplers for short circuit, broken circuit or poor connection, and replace them if necessary and replace the faulty parts if there

exist.

4-11

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. BRAKE SWITCH

COUPLER OF IGNITION SWITCH

TO MAIN CABLE

Open the seat and check the bulb of braking light and rear position light. Repair or replace the taillight assy. if necessary.

Check the front & rear brake switches and their couplers to main cable for short circuit, broken circuit or poor connection. Repair or replace them if necessary.

Check the couplers of winker and front position light to main cable for short circuit, broken circuit or poor connection. Repair or replace them if necessary. Check the

relative light sockets for short circuit, broken circuit or poor connection. Repair or replace them if necessary. Check the relative parts and replace them if necessary.

4-12

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. to main cable for continuity. Repair or replace them if necessary. Check the main cable, meter,

gearshift switch, fuel sensor, etc. for proper function as follows: Disconnect the relative couples and check if the gearshift switch, meter indicators circuit, meter

indicator lights, main cable, fuel sensor, etc. are in good condition by connecting them to a D.C. 12V battery with a multimeter. Repair or replace them if necessary. If

the odometer is faulty, please check the speedometer, its cable and its coupler to meter, and repair or replace them if necessary. If the meter is faulty and the external

circuit is in good condition, please check the internal circuit for short circuit, broken circuit or poor connection, and repair or replace them if necessary. Then check

all the parts of meter, repair or replace the meter if necessary.

Disconnect the fuel sensor to main cable, measure the resistance between the two leads of fuel sensor with multimeter. When fuel level is at the highest, the standard

resistance should be within 6Ω-10Ω. When fuel level is at the lowest, the standard resistance should be within 95Ω-101Ω. Please check the fuel sensor leads and

resistance board if the measured values differ considerably from the standard values. And replace them if necessary.

When the gearshift switch is set into a certain gear, the gear line will be connected to the battery negative leads or engine housing. At this time the gearshift indicator

should show the current gear number. When the turn signal switch is set to left/right, or the dimmer switch is set to high beam, the corresponding meter indicators

should show left/right or the high beam indicator should light up. When pressing the horn button, the horn should sound normally. When the lighting switch is set to

position light or headlight, the front and rear position light and headlight should light up at the same time. Check the relative parts and replace them if necessary.

COUPLER OF SPEEDOMETER

TO METER

COUPLER OF SPEED SENSOR

SPEEDOMETER

TO METER

METER

4-14

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

Do.

The front position light is out of work.

Do.

Lighting switch and

Poor connection, broken circuit

The position light or high beam indicator is out of work.

Repair or replace the faulty switch.

dimmer switch

or damage in internal circuit

Turn signal switch

Do.

The winker are out of work.

Do.

Flashing relay

Internal damage

Do.

Replace the flashing relay.

Poor connection or damage in

Front/rear brake switch

The brake light keeps steady on or fails to light up.

Replace the brake switch.

the switch

Rear position light and

Internal damage

The rear position light and brake light fail to light up.

Repair or replace the light.

brake light

Poor connection, broken circuit

Horn button

No/abnormal horn sound.

Repair or replace the horn button.

or damage in internal circuit

Broken circuit or damage in the

Horn

Do.

Replace the horn.

horn

Poor connection when shifting

Gearshift switch

The gear indicator fails to display the current gear number.

Replace the gearshift switch.

gears

Fuel sensor

Internal damage

The fuel gauge fails to indicate correctly.

Replace the fuel sensor.

Internal parts are damaged.

The meter fails to indicate correctly.

Repair or replace.

Do.

The indicators are out of work.

Do.

Meter

Do.

The corresponding lights/meter are out of work.

Do.

Odometer is damaged.

The odometer or tachometer fail to indicate correctly.

Do.

Meter cable

Cable is broken.

The meter backlight and signal system are out of work.

Replace meter cable.

4-15

4.4

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.

COUPLER OF IGNITION SW. TO

BULB AND SOCKET OF

COUPLER OF LICENSE PLATE LIGHT

SOCKET AND COUPLER OF

MAIN CABLE

HEADLIGHT

TO MAIN CABLE

LICENSE PLATE LIGHT

If the headlight fails to work, open the meter housing and headlight housing, check the relative couplers for continuity and check the relative parts for damage. Repair

or replace them if necessary. Check ignition switch, coupler of license plate light to main cable, couplers of headlight, dimmer switch, etc. to meter for continuity.

Repair or replace them if necessary. Disassemble the headlight and license plate lamp if necessary, check the circuit element and light socket, repair or replace them if

4-16

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.

When the vehicle is started, the headlight will light up: If the dimmer switch is set to low beam at this time, the headlight will provide low beam lighting. If the

dimmer switch is set to high beam at this time, the headlight will provide high beam lighting.

When the ignition switch is turned on, the license plate light will light up.

COUPLER OF DIMMER SW. TO METER

4.4.2 Troubleshooting to Lighting System

Description

Damage Form

Trouble Symptom

Remedy

Magneto

Low output voltage, low brightness, or insufficient battery

Short circuit

Replace the coil.

charging/lighting

charging

coil

Broken circuit

No output voltage, low brightness, or battery fails to charge.

Do.

The headlight is improperly installed.

The lighting beam is improper.

Adjust the headlight.

Headlight

The filament is burnt.

The headlight fails to work.

Replace the bulb.

License plate light

Internal damage

The license plate light fails to work.

Repair or replace.

Poor connection, broken circuit or

Dimmer switch

The headlight or license light fails to work.

Repair or replace the switch.

damage in internal circuit

4-17

4.5

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. For the removal, installation and maintenance of the charging system and ignition system, please refer to the previous

chapters.

4.5.1 Removal, Installation and Maintenance of Electric Starting System

Turn on the ignition switch and check the electric starting system.

COUPLER OF BATTERT POSITIVE LEAD TO MAIN CABLE

COUPLER OF STARTING RELAY TO MAIN CABLE

IGNITION SW.

COUPLER OF STARTING

MOTOR POSITIVE LEAD

TO STARTING RELAY

ELECTRIC

STARER

BUTTON

COUPLER OF GROUNDED WIRE OF MAIN

CABLE TO ENGINE HOUSING

COUPLER OF BATTERT NEGATIVE

FUSE

COUPLER OF STARTING RELAY COIL TO

LEAD TO MAIN CABLE

MAIN CABLE

STARTING MOTOR

COUPLER OF STARTING MOTOR POSITIVE LEAD WIRE

STARTING MOTOR POSITIVE LEAD WIRE

STARTING MOTOR

4-18

COUPLER OF IGNITION SW. TO MAIN CABLE

COUPLER OF MAIN CABLE TO METER

FR. BRAKE SW

COUPLER OF ELECTRIC STARTER BUTTON TO METER

RR. BRAKE SW. AND ITS COUPLER TO MAIN CABLE

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. Repair or replace them if necessary. Check the relative parts for internal damage, short circuit, broken

circuit or poor connection, and repair or replace them if necessary.

4.5.2 Troubleshooting of Electric Starting System

Description

Damage Form

Trouble Symptom

Remedy

Short circuit or broken circuit in the coil.

The starting motor and vehicle fails to start.

Replace the relay.

Starting relay

The starting motor runs abnormally and the vehicle

Internal damage

Do.

fails to start.

All switches

Internal damage or poor connection

The starting motor and vehicle fails to start.

Replace the fault switches.

4-19

4.6

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.

4.6.1 Battery Maintenance

(1) Battery 12V6Ah (model:MTX7L-BS): is of maintenance-free type. The electrolyte is filled in the sealing shell by the manufacturer before leaving the factory,

which fundamentally eliminates the acid leakage in common lead-acid batteries and the inconvenience of frequent filling of electrolyte or distilled water, so there’s

no need to check or replenish the battery electrolyte. However it's important to note that the sealed electrolyte cap should never be removed. If the vehicle is not used

for a long time, remove the battery, charge it, and store it in a cool, ventilated place.

Adding electrolyte: Electrolyte should be added to the unused battery first. After adding the electrolyte to battery, reinstall the battery plug in place to avoid

electrolyte leakage. Warning: The main component of electrolyte is sulfuric acid which is corrosive, so reliable protective measures must be taken if it comes into

contact with skin or eyes, which will cause severe burns.

Charging method: The battery can reach 75% of rated capacity after adding electrolyte and placing for 20 minutes and can be used without charging in this case.

When conditions permit, it's better to use the battery after additional charge. Generally it takes 3 hours to charge with 1A current, but it is best to charge with 0.6A

current for 6 to 8 hours.

4-21

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.

(2) Clean the battery terminals: Turn off the ignition switch, open the seat, and disconnect the negative and positive leads from battery. Clean the battery terminals

with wire brush as shown in the figure. After cleaning, coat the terminals with a thin layer of grease, and connect the battery cables in reverse order of removal.

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

4.6.2 Replacement of Fuse

(1) Before checking and replacing the fuse, turn off the ignition switch so as to prevent an accidental short circuit.

(2) Open the seat, barrel cover and battery protective cover, and the fuse is located in the fuse box near the battery.

(3) Open the fuse box, and check if the fuse is burnt. If the fuse burns frequently, it usually indicates an overloaded circuit or a short circuit. The fault should be found

out and eliminated before normal use.

(4) Replace the fuse as follows: Open the fuse box cover, lift the metal clips at both ends of fuse and the fuse, push the metal clip from the fuse end. Then install the

new fuse into the clips and put on the cover.

(5) Replace the fuse with a new one with the same specification (15A).

WARNING：It's strictly forbidden to take other materials, other ways instead or remove the fuse to connect with the vehicle circuit, which may cause the

vehicle burning.

(6) Reinstall the parts in the reverse order of removal and check if all wire clamps are securely installed.

4-22

4.7

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. Release the front brake handle or rear brake pedal, the brake light will be off. Adjust the rear brake switch as follows if necessary: Unscrew the locknut,

and tighten the adjusting nut. Then tighten the locknut after adjustment.

2) Winker

Turn on the ignition switch, and operate the turn signal switch to check the front left/right or rear left/right winker for proper function.

3) Headlight, front position light, rear position light

Turn on the ignition switch, and operate the dimmer switch to check the headlight, front or rear position light for proper function.

4.7.2 Horn

1) Function

HORN

Turn on the ignition switch, and press the horn button to check if the horn works normally.

2) Fault

Please refer to 4.3 Signal system and meter for the inspection and maintenance of horn.

COUPLER OF HORN TO METER

Check the horn button for short circuit, broken circuit and poor connection, and repair or replace

it if necessary. If the horn fails to sound or sound weakly, turn the adjusting screw of horn sound.

If the horn is determined to be broken, replace it with a new one with same specification.

ADJUSTING SCREW OF HORN

No horn sound is one of the common troubles, which can be divided into two types, one is the

SOUND

electric circuit fault, and the other is an internal fault.

(1) Check electric circuit fault

When the horn fails to sound, first check the fuse for proper function, then check the horn power supply line. If they're in good condition, it indicates that an internal

fault occurs to the horn.

(2) Internal fault

Nowadays, as the technology of various production manufacturers is improving, the internal faults of the horns are becoming relatively less and less. For some of

them, the frequency of use can even reach more than 100,000 times without faults. However, there still exists some common faults such as erosion appearing on the

connectors, damage to coil, diaphragm broken and so on, among which, erosion appearing on connectors is the most common fault. There is often a process of

4-23

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.

Comparing such information with the stored information, the ECU calculates

and outputs the control signal. ECU can not only control the fuel supply

accurately instead of a traditional carburetor, but also greatly improve the

engine performance by controlling the ignition advance angle and idle speed air

flow etc.

5.1.4 Composition of EFI System

5.1.2 Advantages of EFI Motorcycle

5-1

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. ECU can process various

information to realize ignition control, start control and idle speed control etc. In

addition, ECU can connect with the instrument to provide RPM and temperature

signal, with the diagnostic scanner for malfunction diagnosis, with the ECU

anti-theft device to realize the anti-theft control.

Installation Location

ECU can be installed in any place, but it must be far away from the high

pressure transformer to prevent interference.

5-3

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,

ECU fails to detect the effective speed signal, the fuel pump will stop; when the

invalid bracket vibration, invalid seal ring.

engine starts to work, the fuel pump will run unless the ECU detects at least 2

5.3.3 Throttle Valve Body Assembly

effective speed signals of missing teeth. Without speed signal, the fuel pump

Function

will stop.

It is installed in the EFI device to monitor opening angle of throttle valve, and

NOTE: For long-term parking (more than 30 days), especially in summer, be

output voltage signal to electronic controller as the load signal of engine and so

sure to drain off fuel to avoid fuel deterioration and gel matter to damage the

as to judge the working condition of engine.

fuel pump.

Installation Location

The throttle position sensor (TPS) is installed on the throttle valve body and

Generally, the bottom installed built-in fuel pump is installed in the bottom of

fixed with a M5 screw after the initial value is adjusted. The throttle valve shaft

the fuel tank. However, the top installed type is installed in the top. It is

can rotate flexibly and has a output voltage 0.58-4.8V after the sensor is

necessary to ensure that the mounting surface is smooth without oil leakage.

power-on. Initial factory setting for output voltage is 0.58-0.65V.

TPS

FUEL PUMP

STEPPER MOTOR

IAT SENSOR

Fuel Pump Parameters

IAP SENSOR

Item

Reference Value

Working voltage (V)

8~15

Fuel system pressure (KPa)

300

5-5

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°

Installation Location

Throttle valve position turning angle:0°

It is located on the intake manifold

(2) Adjustment method

or connects with it through a rubber

To increase the TEV opening, clockwise adjust the by-pass bolt; to decrease the

hose. The installation surface must be

TEV opening, counterclockwise adjust the by-pass bolt. It is recommended to

level and keep the vent port downward.

turn 1/4 of one lap each time and wait 15s before next adjustment.

If due to structural restrictions, the

Malfunction Mode

inclination angle of the mounting surface

Invalid sensor due to short-circuit, break-circuit, water entering or mechanical

should be not greater than 20°to avoid

IAP SENSOR

failure.

condensed water gathering.

Installation Location

The throttle valve body is installed between the intake manifold and the air

Pin Definition

cleaner.

THROTTLE VALVE BODY

5-6

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. If the cylinder head temperature is not less

to air/fuel ratio, and test the oxygen content in

than 90℃, and the engine speed is around 1500r/min (1600 r/min for scooter),

exhaust gas to determine whether the air and

the stepper motor steps range from 20-60 (depending on the vehicle model).

fuel were completely burned, so as to ensure

that the three-way catalytic converter has the

maximum conversion efficiency of HC, CO

and NOX in exhaust gas.

Installation Location

STEPPER MOTOR

The oxygen sensor should be installed on the muffler or cylinder head, and can

meet the specified temperature range. The installation location should be as

close to the engine as possible and its angle to the horizontal plane should be ≥

20°.

5.3.6 IAT Sensor

NOTE: It is necessary to ensure that the installation seat is well sealed.

Function

The IAS sensor is a negative temperature

coefficient (NTC) thermistor, uses its

temperature sensitive characteristics to convert

the change of ambient temperature into the change

of thermistor resistance, then converts this change

into a voltage signal and outputs to ECU through

a voltage divider circuit.

IAT SENSOR

Malfunction Mode

Incorrect thermistor resistance, short-circuit or break-circuit sensor.

5-7

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

circuit of oxygen

thermistor, which uses its temperature sensitive characteristics to convert the

fuel consumption,

sensor

after stabilizing the

sensor)

change of engine temperature into the change of thermistor resistance, then

engine speed

throttle for 40s

3. 0.42-0.44V

converts this change into ECU through a voltage signal. The thermistor

decreases sharply

(engine is not

resistance value decreases as the engine temperature rises, but it is not a linear

at stable throttle

started)

relationship. The NTC thermistor is installed in a copper heat conducting

sleeve.

Characteristic Parameters

Installation Location

Item

Value

The sensor is mounted on the cylinder head, cylinder block or thermistor.

Storing temperature (℃)

-40~100

Thread of cylinder temp. sensor: M10×1.5

Taper thread of water temp. sensor: M10×1.25

Probe tube end working temp. (℃)

200~850

Connecting plug temp. (℃)

<120

Max. allowable working temp. of probe tube when

930

heating (℃)

Rated voltage (V)

Continuous working voltage (V)

12~14

Test voltage (V)

Malfunction Mode

Failure of heating elements, failure of sensing elements, broken ceramic tube,

5-8

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

Rated resistance at 20℃

2.5 ±5%

Continuous working temp. of injector (℃)

-40~110

Malfunction Mode

Resistance range of injector at 20 ℃ (Ω)

12~16

Incorrect resistance, short-circuit or break-circuit of sensor.

Malfunction Mode

Blocked injector, break-circuit or short-circuit of magnetic coil, failure of

5.3.9 Injector & Oil Rail

injector due to vibration, oil leaks from seal ring.

1) Injector

2) Oil rail

Function

The injector injects fuel in a specified time in accordance with the directive of

The oil rail is of simple structure, used to inject fuel from oil hose to injector,

ECU, thereby providing fuel to engine and atomizing it.

and has the function of storing oil and pressure, reducing fluctuation in oil

NOTE: Different types of fuel injector are used in various motorcycles, so they

pressure.

cannot be shared.

Installation Location

It is mounted on the intake manifold or throttle valve body with a bolt as shown

It is installed on the intake manifold and straight length from the intake valve is

above.

70-120 (mm).

5.3.10 Relay

OIL PUMP

RELAY OUTPUT

Pin Purpose

12V (+)

12V BATTERY (+)

ELECTRONIC

ECU-OIL PUMP

DOOR LOCK 12V

RELAY CONTROL

POWER (+)

INJECTOR

LINE

OIL RAIL

Installation Location

The relay is installed on the engine or frame.

5-9

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. At the same time, together with the missing teeth

Function

position of the sensor signal, it can detect the crankshaft position, so as to

It is used in the EFI device to receive ECU ignition signal and provide high

determine the TDC position which can be one of the parameters for calculating

pressure to ignite the spark plug, so as to ignite air/fuel mixture in the cylinder

the ignition advance angle.

through high pressure connection wire and spark discharge from the spark plug.

Installation Position

Installation Location

It is located in the position of the original carburetor.

The ignition coil is installed on the frame.

ENGINE SPEED SENSOR

IGNIITION COIL

Characteristic Parameters

36-2 TEETH MAGNETO ROTOR

Working voltage

Primary resistance (Ω)

Secondary resistance (KΩ)

Malfunction Mode

(V)

Large clearance between sensor and teeth plate, loose teeth plate, iron fillings

6-16

4.5±10％

18.5±10％

on the sensor, damaged leading wire, short-circuit or break-circuit of sensor..

Malfunction Mode

Break-circuit of primary windings, secondary windings are short-circuited by

breakdown.

5-10

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

Intake Air Manifold Pressure

the system fails, ECU will start the backup function of “emergency control

plan”.

(2) Malfunction can be classified into “steady-state malfunction” and

Oxygen Sensor

“occasional malfunction” (such as temporary break-circuit or poor contact of

couplers). Steady-state malfunction: a malfunction identified by the ECU exists

Crankshaft Position Sensor

for a longtime. Occasional malfunction: a malfunction exists by chance.

5.4.2 MIL Function

TPS

(1) The MIL is set in the vehicle instrument as shown in the picture. All sensors

and actuators in the system can be detected. If a fault is detected, the MIL will

Engine Temp. Sensor

flash in different frequency to remind the driver or maintenance personnel to

read the fault code, and the fault can also be read by the fault diagnostic

scanner.

(2) When the key switch is turned on but the engine is not started, the MIL will

be on for 2~3s, if the current system has no fault, the MIL will be off. Otherwise,

it will flash in regular code rule as the table below.

(3) Flashing rule: A fault code is composed of two digits which stand for the

number of flashes. There is an interval between the light on and the next time.

The decimal digits flash first and longer than the single digits, the two digital

flashes have an interval of about 1.5s. When more than two faults are read, the

interval time will be longer.

Clear Malfunction in ECU: Use the fault diagnostic scanner to call up the

Clear Fault item and select it, and then click the OK button.

NOTE: After troubleshooting, the fault information stored in the ECU should

MIL

be cleared.

5-11

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

Ignition advance

check, repeat above operation until it returns to the standard value.

deviate from the normal range,

-0.2-(+6.0) °

angle

2. When the angle is small, clockwise turn the idle speed bypass screw by

and the idle speed can be

stable at this time.

1/4 of a lap, accelerate the throttle 3 times and wait for 15s to check, repeat

above operation until it returns to the standard value.

1. When the time is longer, problems maybe: blocked injector port, oxygen

sensor continues to report dilute mixture, insufficient fuel pump pressure or

battery voltage, air leaks from muffler gasket or mounting seat of oxygen

Working condition: idling at

Injection time

2.5-3.5 ms

sensor.

warm engine

2. When the time is shorter, problems maybe: oxygen sensor continues to

report thick mixture or faulty sensor oxygen, fuel pump pressure is higher

than normal value.

Large fluctuation from 0.01 to

1. When the value keeps below 0.44V, the air-fuel mixture in combustion

0V: short-circuit of oxygen

0.99V (after the engine works

chamber is too lean.

sensor

Oxygen sensor

normally for 40s)

0.44V: open-circuit of oxygen

2. When the value keeps above 0.6V, the air-fuel mixture in combustion

sensor

chamber is too rich.

1. A fault may occur when temperature of the water/cylinder temperature

The temperature rises as the

sensor changes little as the engine temperature rises greatly.

Water/cylinder

engine runtime increases, but peak

2. A fault may occur if the temperature continues to show a certain value

Replace the sensor

temp. sensor

temperature should not be more

or greatly exceeds the actual value.

than 120℃.

3. The water/cylinder temperature sensor reads abnormal data, the fan

keeps on rotating or fails to work.

5-12

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

TPS

0-80%

2. Opening at idle speed condition shows 0 or 0.39%.

cannot rotate freely.

The atmospheric pressure

1. No idle speed, slow response in acceleration;

needs to be calculated

IAP sensor

Idle speed: about 30Kpa

2. Faulty magneto speed sensor, air leaks from connecting hose or poor

according to the altitude of the

contact of circuit.

actual region.

1. Check the charging device and circuits at low voltage;

Battery voltage

13.5-14.5V

Check at stable idle speed

2. Check the rectifier at high voltage.

NOTE: When the altitude is higher than 1Km, the idle speed adjustment cannot refer to the TEV opening, but the target idle speed (1600±100) r/min, (1300±100)

r/min and the ignition advance angle (-0.2~6)

°C. It is also possible to determine whether the bypass bolt adjustment is proper by accelerating or decelerating the

throttle. When the cylinder head temperature reaches (90±3)

°C and the throttle keeps at 4000r/min, loosen or rotate the throttle rapidly after 15s to determine

whether the engine speed can return to the target idle speed by engine sound. If the fuel returns slowly, it indicates that air supply of the bypass bolt is too large. If

there is an engine flameout at fuel return or fuel adding, air supply of the bypass bolt is too small. In both cases, the bypass bolt needs to be adjusted to ensure the

vehicle in best condition.

Target idle speed for scooter: 1600±100 r/min

Target idle speed for other vehicles: 1300±100 r/min

5-13

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

Fuel pump is electrified.

Low voltage (＜8V )

Check the battery, system relay and couplers for normal work.

Lack of fuel

Add fuel and amount should not be less than 3L.

Low battery voltage

Check if the battery, voltage regulator and magneto need to

charge.

No fuel

pressure or

Seriously blocked fuel passage

Check the fuel filter strainer for block

low fuel

Engine

pressure

Failure of fuel pressure regulator

Replace the fuel pump

fails or is

Leakage of fuel passage

Broken hose or loose hose clamp, replace them if necessary

hard to

start, is

Fuel pump wires in reverse connection

Reconnect

easy to

flameout

Fuel

Fuel in spark plug is wet (fuel is not burned)

Remove and dry the spark plug, or replace it

pump can

Creepage of spark plug insulator or abnormal

Replace the spark plug or spark plug cap

work

jump-spark

Sparks

Improper spark plug gap

Adjust it to standard value

occur in

Normal fuel

ignition

Poor contact or creepage of spark plug cap

Adjust or replace

pressure

coil at

Faulty ignition circuit or poor contact of

Check the wires, TPS installation condition and various

high

couplers

couplers.

pressure

Damaged water/cylinder temp. sensor or IAT

Replace

sensor

Blocked injector

Clean or replace

5-14

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 in

ignition

Damaged ignition coil or spark plug

Replace

coil

high

Creepage of ignition coil output

Replace

pressure

Faulty ECU or poor contact of couplers

Check or replace

Clogged air cleaner or too much dusty on it

Clean off

Heavy carbon deposits in combustion chamber and

Clear away

exhaust muffler

Worn piston rings, piston and cylinder, large gaps

Replace

Lack of power

Slipping clutch friction disc

Adjust or replace the clutch friction disc

Clogged fuel passage, lower fuel pressure or poor quality

Check the fuel pump, injector and fuel for good condition

fuel

Faulty water/cylinder temp. sensor or faulty oxygen

Check and replace

sensor

Poor quality fuel

Use higher quality fuel

Engine failure

Repair

Large fuel consumption

Faulty water/cylinder temp. sensor

Check and replace

Faulty oxygen sensor

Check and replace

Clogged air cleaner or too much dusty on it

Clean off

5-15

Battery voltage＜ 12V

Check the battery and charging system

Poor contact of ECU or injector couplers

Check and troubleshooting

Air leaks from throttle valve body or connecting hose of

Check the paper gasket, O-ring, clamp or connecting hose for

inlet pipe

air leakage

Dirties in throttle valve body or clogged air cleaner

Clean off

Check the fuel tank for enough fuel, check the fuel filer and

Influent fuel passage

fuel passage for clogging

Expired fuel or poor quality fuel

Use unleaded gasoline with RQ92 or higher

Loose spark plug

Tighten up

Unstable idle speed

Improper spark plug gap

Adjust to stand value

Poor contact or creepage of spark plug cap

Adjust or replace

Creepage or abnormal jump-spark of spark plug

Replace the spark plug

insulator

Small valve gap or engine failure

Adjust the valve gap or check the engine

Air leaks from muffler gasket or oxygen sensor

Check and troubleshooting

mounting seat

Air leaks from connecting pipe of idle speed gulp valve

Check or adjust

or TEV opening isn’t suitable

Invalid oxygen sensor or little air supply of idle speed

Check, adjust or replace

gulp screw

5-16

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

Check and replace

Insufficient power generated from magneto coil

Check and replace

Low voltage of EFI system (＜12V)

Aging battery can’t store power

Repair, maintain or replace

Avoid driving at low speed for a long time or connecting with

Insufficient battery power due to heavy load

high-power electrical appliances

Faulty water temp. sensor

Check and replace

The fan keeps rotating or fails to

rotate

Faulty fan relay

Check and replace

Engine is easy to stall when releasing

Large TEV opening or little idle gulp air

Adjust the adjusting screw of idle gulp valve

the throttle

Damaged or leaking negative pressure switch cap of

Check and replace

carbon canister

Large intake air of idle gulp valve screw

Adjust

Too high idle speed

Air leaks from inlet pipe or O-ring

Check and repair

Broken or leaking desorption tube, idle gulp valve,

Replace the abnormal rubber hose

negative pressure pipe, etc

5-17

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

Clutch friction discs are burned and worn.

Replace

Large gap of clutch cable, not disengaged clutch

Adjust

Difficulties in gear-shifting

Tight drive chain

Adjust

Check the gearshift cam, gearshift shaft, main shaft &

Failure of engine gear-shifting device

countershaft, gearshift drum and gearshift pedal

Faulty engine speed sensor (exciter coil)

Replace

Large gap between engine speed sensor (exciter coil)

Adjust

and rotor convex plate

Poor contact of main cable with ignition coil coupler

Check and adjust

No spark of ignition coil

Poor contact of ECU and main cable, or faulty ECU

Check and replace

Poor contact of engine speed sensor and main cable

Check and repair

coupler

Descriptions: When EFI vehicles have problems, please refer to the maintenance method of the carburetor vehicle and check it from the following aspects:

1. Check the vehicle for sufficient fuel (must be≥3L with good quality) and normal fuel supply.

2. Check the ignition system for normal work.

3. Check the engine cylinder or normal pressure.

4. Check the engine intake system for fluent flowing.

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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. Adjust the slack to be 10~20mm.

ANTI-ROLL VALVE

ACTIVE CARBON CANISTER

OIL/GAS SEPARATOR

CHECK VALVE

AIR CLEANER

6.1.2 Adjustment

Loosen the locknuts of rear axle and drive chain adjuster; turn the adjusting bolt

MUFFLER

ENGINE

until the left and right adjuster align with the same mark: finally, check and

tighten up the rear axle locknut with tightening torque 60~80 N

6.1.3.1 Removal, Installation and Maintenance

1) Turn off the ignition switch.

2) Unlock the seat with a key and turn over the seat cushion.

3) Remove the fuel tank cover, check the seal ring and replace it if it deforms or

damages.

4) Remove the fuel pump and check the filter hose and strainer, clean them if

necessary.

5) Remove the fuel tank, check the fuel tank interior and clean the tank if

necessary.

6) Check all rubber hoses in fuel system for bend, breach and aging, adjust or

replace them if necessary.

6-1

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.

6.1.4 Principle of Secondary Air-Induction System and Crankcase EGR System

The crankcase EGR system has a gas channel between the crankcase and the air cleaner, and sets up an oil/gas separator. Exhaust gas in the

crankcase passes through the oil/gas separator, then enters the air cleaner, throttle valve body assembly, and returns to the engine combustion

chamber for combustion, avoiding direct discharge of exhaust gas into the atmosphere in the crankcase, thus reducing atmospheric pollution.

Precautions during use and maintenance: The oil/gas separator should be cleaned regularly, and it is recommended to do so every 3 months.

6.1.5 Check of Fasteners

Check all fasteners such as rear fork shaft, front/rear wheel with a torque spanner as pictures below.

REAR FORK SHAFT

FRONT WHEEL

REAR WHEEL

MUFFLER

TIGHTENING TORQUE:

45～65N.m

60～80N.m

24～30N.m

6-2

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. Tyres--Check condition and pressure.

5. Battery--Check its power.

6. Accelerator--Check for accelerator operation, cable connection and free play of handle, adjust or replace if necessary.

7. Lights and horn--Check that headlights, taillight, parking (position) light, winkers, indicators and horn function properly.

8. Drive chain--Check chain slack and engine oil condition, adjust, lubricate or replace if necessary.

9. All nut, bolts and fasteners--Check that the parts are mounted securely.

10. Steering system--Check for its flexibility and reliability.

6.3 GENERAL MAINTENANCE

6.3.1 Tool Kit

1. Screw driver grip

1pc

2. Double-ended screw driver

1pc

3. Spark plug wrench, 16#×18＃

1pc

4. Open-ended spanner, 8mm×10mm 1pc

5. Open-ended spanner, 13mm×15mm 1pc

6. Tool bag

1pc

Manufacturer’s Vehicle Repair and Maintenance Information

Web site addresses referred to

http://www.lifanmotos.net/product

Account: n.a.

Password: n.a.

6-3

6.3.2 Maintenance Schedule

FREQUENCY

Item

ODOMETER READING, km (Note ②)

SERVICE ITEM

Period

1,000km

4,000km

8,000km

12,000km

Note

Fuel line system

Ⅰ

Fuel filter

Throttle operation system

Ⅰ

Air cleaner element

Note ①

Spark plug

Ⅰ

Valve clearance

Ⅰ

Engine oil

Yearly

Every 2,000Km after 500km & 1000km

Engine oil strainer

Yearly R

Cam chain slackness

Drive chain

Ⅰ、L

Battery

Monthly

Ⅰ

Brake shoes/pad wear

Ⅰ

Brake system

Ⅰ

Stop light switch

Ⅰ

Headlight adjustment

Ⅰ

Clutch

Ⅰ

Side stand

Ⅰ

Suspension

Ⅰ

Nut, bolt and fasteners

Ⅰ

··

Wheels/spokes

Ⅰ

··

Steering, handlebar and bearing

Ⅰ

6-4

Maintenance work should be performed in light of Maintenance Schedule.

Letters in the table indicate as follows:

I：Inspect and clean, adjust, lubricate or replace if necessary.

C：Clean

R：Replace

A：Adjust

L：Lubricate

NOTES: ① Clean more frequently when riding in unusual wet or dusty areas;

② At higher odometer readings, still follow the frequency intervals established in this manual.

6.4 STORAGE

1. Empty fuel inside the fuel tank, fuel hose and other passages.

2. Remove the spark plug and pour appropriate engine oil into its hole. Turn off the ignition switch, and crank several revolutions to scatter evenly the oil on the

cylinder wall.

3. Remove the drive chain, clean and lubricate it.

4. Lubricate all of the controlling cables.

5. Support the motorcycle with the center stand, store it in the atmosphere and dry place.

6. Seal the muffler outlet with a plastic bag to prevent moisture from entering.

7. Coat all surfaces of bare metal with a thin layer of rust-resisting oil if the motorcycle is to be exposed to wet or salty air.

8. Remove the battery and store it in a dry, cool and well-ventilated plate. Charge the battery once every 30-day.

6.5 UNPACKING

Place the packed motorcycle on a level ground. Unpack the case with a special tool to prevent scratching the body surface. This done, check to see that all parts of the

motorcycle are intact and good, check the allotted tools for completeness.

6-5