Lifan LF200-10P Manual Download Page 43

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2-35

2.5.2 Troubleshooting to Crankcase

Description

Damage Form

Trouble Symptom of Component

Trouble Symptom of Motorcycle

Remedy

Crankcase

Cracks on the crankcase

Oil leakage through crankcase

Repair or replace

Threads on the crankcase are
damaged

Oil

leakage

between

RH/LH

crankcases

Repair or replace

Threads of cylinder are damaged

Gas leakage between cylinder head
and cylinder due to loose of
cylinder nuts

Engine fails or is hard to start.
Engine lacks power. Unstable idle
speed

Trim the threaded hole or replace the

crankcase

Bolt of cylinder is broken

Do.

Replace the broken bolt with a new
one

Oil seal is damaged

Oil leakage through oil seal

Replace the oil seal

Right Crankcase

Cover

Damaged or cracks on the right
crankcase cover

Oil leakage through right crankcase
cover

Repair or replace right crankcase
cover

Gasket is damaged

Oil leakage between right crankcase
and cover

Replace the gasket with a new one

Left Crankcase

Cover

Damaged or cracks on the left
crankcase cover

Oil leakage through left crankcase
cover

Repair or replace left crankcase
cover

Gasket is damaged

Oil leakage between left crankcase
and cover

Replace the gasket with a new one

Water

Pump

Gear

Water pump gear is damaged

Coolant liquid fails to cycle

Engine overheats

Replace water pump gear

Water

Inlet

Cover & Gasket

Gasket is damaged

Water leakage

Replace the gasket with a new one

O-Ring of Water
Pump Gear

O-ring is damaged

Water leakage

Replace the O-ring

Summary of Contents for LF200-10P

Page 1: ...E INTRODUCTION 1 1 1 2 SPECIFICATIONS 1 2 CHAPTER 2 ENGINE 2 1 CYLINDER HEAD 2 1 2 2 CYLINDER BLOCK 2 8 2 3 VALVE TRAIN 2 11 2 4 TRANSMISSION 2 16 2 5 CRANKCASE 2 30 2 6 CRANK MECHANISM 2 36 2 7 START...

Page 2: ...SUSPENSION 3 13 3 5 FRONT AND REAR WHEELS 3 15 3 6 INTAKE SYSTEM AND EXHAUST SYSTEM 3 21 3 7 COOLING SYSTEM 3 25 CHAPTER 4 ELECTRICAL COMPONENTS AND METER 4 1 CHARGING SYSTEM 4 4 4 2 EFI SYSTEM 4 7 4...

Page 3: ...4 32 4 7 BATTERY AND FUSE 4 34 4 8 ELECTRICAL HORN 4 36 CHAPTER 5 SERVICE 5 1 ROUTINE MAINTENANCE AND ADJUSTMENT 5 1 5 2 PRE RIDE INSPECTION 5 4 5 3 GENERAL MAINTENANCE 5 3 1 Tool Kit 5 4 5 3 2 Maint...

Page 4: ...the structure as well as service and repair skill Lifan Industry group Co Ltd is continually striving to improve all its models All information in this publication is based on the latest product infor...

Page 5: ...nsportation Installed on the vehicle is 165MJ P engine which is of vertical single cylinder 4 stroke and air cooled type The vehicle 7 Exhaust muffler Main step Radiator Front Wheel Gearshift pedal Si...

Page 6: ...placement 198 ml Compression ratio 11 1 Carburetor type EFI Air cleaner Plastic housing with paper and foam element Lubrication Press splash Starting mode Electric Max net power 12 5kW 8000r min Max t...

Page 7: ...2nd 1 867 3rd 1 316 4th 1 000 5th 0 833 Drive chain Type 08MC Link No 126 Brake Front Disk Rear Disk Electrical Ignition Inductive energy storage Static ignition timing CA 40 Spark plug CPR8EA Spark...

Page 8: ...eam indicator LED 8mA urn signal indicator LED 8mA Meter light LED 8mA Fuel Oil Fuel type RQ 93 Fuel tank Capacity 14L Reserve 2 8L Engine oil Brand 15W 40 SF Capacity 1L Damping oil Brand HQ 10 Capac...

Page 9: ...f oil flows from the view hole Clean the oil passage line if necessary NOTE Bolt specification M6 12 Tightening torque of bolt 8 12N m 2 Unscrew the fixing bolt of valve cover and remove the valve cov...

Page 10: ...ck the cylinder head left cover valve cover and the gasket for damage Replace it if necessary 7 Unscrew and remove the fixing bolt M6 10 of the timing driven sprocket Remove the timing driven sprocket...

Page 11: ...and remove the connecting bolt of cylinder head NOTE Hexagon socket bolt specification M6 14 Tightening torque of bolt 8 12N m 11 Remove the cylinder head assembly 12 Remove the split cone valve sprin...

Page 12: ...if it is beyond the limit Standard valve intake 29 0 05mm exhaust 25 0 05mm 15 Measure I D of valve guide If it is out of the limit replace the worn valve guide Service limit 5 54mm 16 Unscrew the spa...

Page 13: ...2 5 17 Unscrew and remove the bolt of thermostat and remove the thermostat NOTE Bolt specification M6 16 Tightening torque of bolt 8 12N m...

Page 14: ...ls or is hard to start Engine lacks power Unstable idle speed Grind the cylinder head surface or replace the cylinder head Defects such as pits erosion etc are found on the contact area of valve seat...

Page 15: ...power Unstable idle speed Replace the damaged spark plug with a new one of the same type Loose park plug Air leakage between spark and cylinder head Engine is hard to start Unstable idle speed Tighten...

Page 16: ...Check them for damage Replace them if necessary 2 Unscrew and remove the fixing bolt of water pipe Remove the water pipe and check the pipe for crack Replace it if necessary 3 Remove the cylinder bloc...

Page 17: ...ase 6 Pull out the piston pin and check it for wear Replace it if it is out of the service limit Service limit 14 95mm 7 Check and measure the cylinder wall If it is out of the service limit replace t...

Page 18: ...d to start Engine lacks power Unstable idle speed Grind the cylinder head jointing surface or replace the cylinder head The cylinder block is worn considerably Cylinder block to piston piston ring cle...

Page 19: ...e valve if necessary 2 Remove the split cones valve spring seat Check them for wear Repair or replace them according to the actual situation 3 Remove the valve spring and check it for wear or deformat...

Page 20: ...mit replace the valve Face angle 45 Margin 1 6mm Measure the diameter of valve stem If it is beyond the service limit replace the valve Service limit 4 95mm 7 Measure the free length of the spring If...

Page 21: ...r holder for excessive wear or inflexible rotation Replace it if necessary Then remove the camshaft assembly Check it for wear and replace it if necessary 10 Unscrew the bolt M6 of left crankcase cove...

Page 22: ...neto until T mark on the rotor aligns with the index mark on the left crankcase cover In this case both the intake and exhaust valves are closed 14 Adjust the intake exhaust valve to 0 05 0 02mm then...

Page 23: ...ls or is hard to start Engine lacks power Unstable idle speed Clear away carbon deposit grind the valve seat Contact area is seriously worn or has defects such as pits etc Do Do Do Valve stem is serio...

Page 24: ...the gasket of right crankcase cover and check it Replace the damaged the gasket with a new one 2 Check the clutch rod for wear Replace it if necessary 3 Check the spring of clutch rod Replace it if n...

Page 25: ...t if necessary 6 Remove the clutch bearing and check it for wear Replace it if necessary 7 Unscrew the clutch locknut with specified equipment Replace it if it is deformed 8 Remove the clutch driven d...

Page 26: ...e primary drive gear and check it Replace the worn gear with a new one 11 Remove the clutch outer comp check the gear for wear Replace the disc if necessary 12 Remove the clutch drive plate Measure th...

Page 27: ...ckness of clutch driven plate Replace the plate if the thickness is out of the limit Service limit 1 4mm 14 Measure the free length of clutch spring Replace the spring if the length is out of the limi...

Page 28: ...f Motorcycle Remedy Clutch outer Hub grooves are worn into saw teeth shaped Friction discs fail to remove freely in the hub grooves Clutch slipping Out of function Abnormal sound Trim the grooves with...

Page 29: ...Check the gearshift cam for wear and replace it if necessary 5 Unscrew fixing bolts from the crankcase remove the right crankcase and check the gasket for damage Replace the damaged gasket with a new...

Page 30: ...it for wear Replace it if necessary 8 Remove the fork I and check it for wear Replace it if necessary 9 Remove the fork II and check it for wear Replace it if necessary 10 Remove the fork III and chec...

Page 31: ...rshift fork shaft If it is beyond the service limit replace the worn shaft with a new one Service limit 11 90mm 14 Measure the thickness of gearshift fork and I D of hole in the gearshift fork by usin...

Page 32: ...and countershaft comp for wear Replace them if necessary it needs to replace the gear if defects such as pits teeth crack appear 17 Remove the washer of starting mid gears Check it for wear and replac...

Page 33: ...ountershaft 1st gear and then check it for wear Replace the worn gear if necessary Limit value of inner bore 19 6mm 21 Remove the bush of countershaft 1st gear and washer I then check them for wear Re...

Page 34: ...for wear Replace the worn gear if necessary Limit value of inner bore 22 1mm 25 Remove the countershaft 5th gear 4th gear and splined washer then check them for wear Replace the worn out part if nece...

Page 35: ...ar from the mainshaft and check it for wear Replace the gear if necessary Limit value of inner bore 20 1mm 29 Take the splined washer and circlip out of mainshaft then check them for deformation Repla...

Page 36: ...2 28 31 Remove the starting driven gear set and washer then check them for wear Replace the worn part...

Page 37: ...h difficulty Do Fork hole is considerably worn Fork to drum gap is too large Do Do Gearshift Drum Groove is worn out Do Replace the worn out drum Gearshift Drum Stopper Excessively worn or damaged Do...

Page 38: ...20 30 N m 2 Unscrew the bolt M6 of right crankcase cover Remove the cover by striking with a rubber hammer Tightening torque of bolt 8 12N m 3 Check the gasket of right crankcase cover for wear Repla...

Page 39: ...of starter motor and idler cover Remove the starter motor and idler cover Check the O ring for wear Replace it if necessary 7 Check the dual gear for wear Replace the gear if there s pit or tooth bre...

Page 40: ...kcase cover for damage Replace it if necessary 10 Unscrew the connecting bolts from the crankcase Tightening torque 8 12N m 11 Unscrew and remove the bolt M6 of water inlet cover Tightening torque 8 1...

Page 41: ...2 33 13 Check the water inlet cover and gasket for wear Replace it if necessary 14 Unscrew and remove water pump gear 15 Remove the right crankcase cover 16 Remove the water pump gear WATER PUMP GEAR...

Page 42: ...2 34 17 Check the water pump gear and O ring for wear replace them if necessary O RING...

Page 43: ...Oil leakage through oil seal Replace the oil seal Right Crankcase Cover Damaged or cracks on the right crankcase cover Oil leakage through right crankcase cover Repair or replace right crankcase cover...

Page 44: ...llowing figure 3 Remove the crankshaft and connecting rod Check the timing drive gear for wear Replace the worn out gear with a new one Note The O mark of timing drive gear should be aligned with cran...

Page 45: ...arings of crankshaft and balance shaft for wear Replace them if necessary 7 Measure the O D of the piston pin with a micrometer If it is beyond the service limit replace the worn pin with a new one Se...

Page 46: ...limit replace the piston ring as a set Limit value Ring 0 5mm O ring 1 2mm Measure the diameter of piston skirt at the position which is 10mm away from the bottom If it is beyond the limit replace the...

Page 47: ...nocking sound of big end bearing Replace the crankshaft connecting Bearing Excessive wear of needle bearing Do Do Do Excessive wear or damage of crankshaft bearing Abnormal sound from the crankshaft b...

Page 48: ...starting shaft and check it for wear Replace it if necessary 3 Check the torque spring of starting for elasticity and replace the spring if necessary For which purpose remove the spring ring and seat...

Page 49: ...necessary 6 Remove the friction spring of starting gear and check it for elasticity Replace it if necessary 8 Remove the snap ring of starting shaft and check it for deformation Replace it if necessar...

Page 50: ...arting is slipping Replace the gear with a new one Gear is damaged Starting is hard Ratchet Ratchet is worn heavily Starting is slipping Starting is slipping Replace the ratchet with a new one Frictio...

Page 51: ...g torque 8 12N m 2 Knocking with a plastic hammer remove the starting motor 3 Unscrew bolts of left crankcase cover Tightening torque 8 12N m 4 Unscrew bolts of mid gear cover and remove the cover Che...

Page 52: ...ssion Check them for wear Replace the worn part 6 Remove the gear indicator and check it Replace or repair it if necessary 7 Remove the magneto wire plate from the left crankcase cover 8 Remove the le...

Page 53: ...agneto remove the rotor of magneto with specified tools Bolt specification M10 35 Tightening torque 40 50N m 11 Check the starting clutch body rollers and springs for wear Replace the worn part if nec...

Page 54: ...2 46 13 Check the coils of both rotor and stator of magneto for damage Replace the damaged part...

Page 55: ...between each commutator piece with broken saw bit 0 5 0 8 mm deeper than the commutator surface Remove the chip and burr between each commutator Armature commutator surface is worn considerably Starti...

Page 56: ...rque 8 12N m 2 Unscrew and remove the bolt of valve cover then remove the valve cover Bolt specification M6 12 Tightening torque 8 12N m 3 Unscrew and remove the locknut M8 of cylinder head Tightening...

Page 57: ...he cylinder block for clogs 6 Check the oil gallery in the crankcase and clean it 7 Remove the oil screen cap M36 1 5 from the crankcase Tightening torque 20 30N m 8 Check the oil strainer and clean i...

Page 58: ...e cover then remove the right crankcase cover Tightening torque 8 12N m 11 Check the oil sight glass for leakage and replace it if necessary Check the oil gallery in the right crankcase cover for fore...

Page 59: ...p check the oil pump for proper functioning Replace the pump if it is out of work 15 Remove the oil pump gear then check it for wear and flexible turning Replace it if necessary 16 Measure the gap bet...

Page 60: ...outer rotor of oil pump is worn heavily Oil is delivered improperly by the oil pump Engine lacks power overheat or excessive wear Replace the oil pump Oil strainer Strainer is clogged Oil is delivered...

Page 61: ...ame Frame is deformed or broken Running off tracking Correct or replace Side stand Deformed or broken Effect of parking Replace the side stand Return spring is damaged Side stand fails to return Effec...

Page 62: ...ning Tighten it and wipe the surface 3 Check the free play of rear brake pedal to see if it is out of the service limit If it is exhaust the air in the rear brake system and check the free play of rea...

Page 63: ...if necessary 6 Check the main footrest for wear Replace it if necessary 7 Check the pillion footrest for wear Replace it if necessary 8 Check the side stand for deformation Replace it if necessary REA...

Page 64: ...place it if necessary 10 Check the seat for break Replace it if necessary 11 Check the fuel tank for leakage Replace it if necessary 12 Check the right side cover for damage Replace it if necessary PI...

Page 65: ...r for damage Replace it if necessary 14 Check the right ornament of fuel tank for break Replace it if necessary 15 Check the left ornament of fuel tank for break Replace it if necessary LEFT SIDE COVE...

Page 66: ...dle 1 Turning the steering handle check it for proper functioning 2 Remove the steering handle check it for deformation Correct or replace it if necessary 3 Unscrew the fixing bolt of steering stem to...

Page 67: ...f necessary 6 Extract the steering stem and check it for wear or deformation Replace it if necessary 7 Before installing the steering stem apply a layer of grease to bottom race of the bearing 8 Tight...

Page 68: ...teering stem moves smoothly and easily and no radial play between the steering and pipe is allowed The race is worn seriously Such defects as pockmarks dints cracks are found Steering handle shakes or...

Page 69: ...e of Front Shock Absorber 1 Unscrew the bolt of top bridge and steering bar 2 Unscrew the bolt of bottom bridge 3 Unscrew the locknuts of front axle Remove the front axle and front wheel 4 Unscrew the...

Page 70: ...om the pipe Check the oil and replace it if necessary 6 Remove the dust seal circlip bottom case etc 7 Remove the oil seal check it for wear Replace it with a new one if necessary 8 Remove the rebound...

Page 71: ...mm 10 Measure the damping spring and replace it if it is out of the limit Service limit 8mm 11 Measure the free length of damping spring Replace it if it is out of the service limit Free length of spr...

Page 72: ...through seal Replace the fork tube Chromium plated part is worn to expose the substrate Oil leakage through seal Replace the fork tube Bottom case Broken deformed or damaged Oil leakage through bottom...

Page 73: ...ance of Rear Shock Absorber 1 Check rear fork to see if it swings Replace the rear fork shaft sleeve if necessary 2 Unscrew the locknut of rear fork shaft 3 Remove the rear fork shaft 4 Check the rear...

Page 74: ...cription Damage Form Trouble Symptom Remedy Rear Shock Absorber Spring is weak or broken Rear shock absorber is too weak or stiff Replace the spring Oil leakage from rear shock absorber Rear shock abs...

Page 75: ...nce 1 Unscrew the locknut of front hydraulic brake Remove the hydraulic brake 2 Unscrew the locknut of front axle and remove the front wheel 3 Check the speed sensor for wear Replace it if necessary 4...

Page 76: ...and check it for wear Replace the oil seal if necessary 6 Check the bearing of front axle for wear Replace it if necessary BEARING 7 Unscrew the adjusting nut of chain Remove the chain 8 Unscrew the l...

Page 77: ...the left bush of rear axle Check it for wear Replace it if necessary 11 Remove the bolt M8 on the rear driven sprocket and remove the circlip Check it for wear and replace it if necessary Tightening t...

Page 78: ...k the bearing of rear axle for wear Replace it if necessary BEARING 15 Check the mounting surface of brake disc Replace the wheel hub if necessary MOUNTING SURFACE OF BRAKE DISC 16 Check the brake dis...

Page 79: ...his action for 10 times Adjust the control force to the degree which is proper for users Less than 200N 19 Exhaust the air in the rear brake after assembly 20 At last step and loosen the rear brake pe...

Page 80: ...xle Replace the oil seal of front axle Poor braking performance Wear braking effect of front hydraulic brake Exhaust the air in the front hydraulic brake See point 16 of 5 2 for detailed steps Rear Wh...

Page 81: ...1 Open the seat lock Disassemble the seat 2 Unscrew the screw of air filter cover Remove the air filter cover and check it Replace it if necessary 3 Remove the element of air filter Check it for dama...

Page 82: ...smoke from the exhaust pipe Remove the element according to 3 6 1 Clean it in cleansing solvent and dry it up Then soak the clement in engine oil SAE15W 40 SE until it becomes saturated and then sque...

Page 83: ...of Exhaust System 1 Unscrew locknut of exhaust pipe 2 Unscrew bolt of muffler 3 Remove the exhaust pipe Check the muffler and mounting bracket for damage Replace or repair if necessary 4 Remove the g...

Page 84: ...asket with a new one Replace the gasket whenever the ex pipe is disassembled Exhaust Muffler The muffler case or mounting bracket is damage Do Replace the exhaust muffler Exhaust Muffler Sealing off i...

Page 85: ...the seat 2 Unscrew the mounting screw on the left ornament of fuel tank Remove the left ornament of fuel tank Mounting screw 3 Unscrew the mounting screw on the right ornament of fuel tank Remove the...

Page 86: ...3 26 5 Remove the fuel tank 6 Remove the hoop of water pipe 7 Unscrew the mounting bolt M6 22 of radiator 8 Remove the radiator and check it for damage or clog Replace it if necessary...

Page 87: ...Damage Form Trouble Symptom Remedy Remark Radiator Clogged Too much dirt coolant liquid no circulation about coolant liquid engine overheats Clean the radiator or replace it Damaged No circulation abo...

Page 88: ...Electrical Components on the Vehicle HEADLIGHT FR POSITION LIGHT FR WINKER FLASHER RELAY BATTERY FUSE CLUTCH SW LEFT HANDLE BAR SW FAN TAILLINGT RR WINKER LICENSE PLATE LIGHT STARTING RELAY STARTING M...

Page 89: ...2 IGNITION COIL HORN METER RECTIFIER RR BRAKE SW SPARK PLUG RESERVED INTERFACE FOR BURGLAR ALARM EFI CONTROLLER DIAGNOSE INTERFACE FOR EFI FUEL PUMP FUEL SENSOR IGNITION SW HANDLEBAR SW RH FR BRAKE S...

Page 90: ...4 3 ELECTRIC DIAGRAM...

Page 91: ...upply the devices with power at the electric power that generator send out is enough and charge toward the battery for storing a part of electric power Therefore make sure to supply the device with el...

Page 92: ...it or broken circuit occurs on the charging lighting coil or the coil is connected with the metal housing Replace the charging lighting coil if necessary Charging coil coupler Y Y Y wire is charging L...

Page 93: ...Replace the charging lighting coil Rectifier with Regulator The rectifier is faulty Charging to battery is insufficient Light is dim The current is too high and the battery is deformed Replace the rec...

Page 94: ...cylinder block or high temperature water passage IAT sensor To measure the air inlet temperature On the air filter Intake pressure sensor To measure the air inflow On the Vehicle Fuel pump To generat...

Page 95: ...or engine rotation speed sensor throttle position sensor TPS and oxygen sensor Working condition of ECU supply range DC 10 14V ambient temperature 25 85 Note Don t charged inserted ECU controller Disa...

Page 96: ...ystem reach the best performance 3 Oxygen sensor OXYGEN SENSOR MUFFLER The oxygen sensor is mounted on muffler It is used to detect the oxygen content in the exhaust gas from the engine and to realize...

Page 97: ...is used to detect engine temperature 5 Intake air temperature sensor IAT IAT Intake air temperature sensor is mounted connected on the air filter or the position close to the filter It is used to dete...

Page 98: ...EFI main relay EFI system is powered by an EFI main relay The fan is powered by another EFI main relay And the two EFI main relays are controlled by ECU controller If there s no power about EFI syste...

Page 99: ...ne Note Direction of airflow Make sure good sealing ability of joint 10 Ignition coil It is inductance type ignition coil with strong ignition energy Note Replace with the same type of ignition coil o...

Page 100: ...ype short circuit broken circuit lost of signal 3 Failure warning There s fault indicating light on the meter so almost all sensors on the EFI system can be detected If fault is detected the fault lig...

Page 101: ...cuit between No 1 and No 3 stitches or if the resistance value changed dramatically YES Replace the sensor NO Replace the ECU 5 Check with multimeter to see if there s short circuit or broken circuit...

Page 102: ...titch and vehicle ground wire green YES Repair or replace the cable NO Next step 5 Insert the oxygen sensor plug on the cable Set it to neutral gear Start the engine and make it in idle speed till the...

Page 103: ...for clogging 4 Check the connection of throttle body and air inlet pipe for proper sealing 5 Check the high voltage wire of ignition coil for breakage and aging 6 Check the connection of the wires for...

Page 104: ...ge Check the fuel coarse cleaner and fine filter Failure of fuel pump or fuel pressure adjuster Replace fuel pump or fuel pressure adjuster Insufficient voltage Check the battery rectifier and magneto...

Page 105: ...2 The key switch should be set to off position to avoid damage when disassemble the ECU 3 The power line should not be remove from the battery when engine or electric system is working 4 The engine ca...

Page 106: ...well but do not use the cloth which drops fiber 4 If the opened components will not be repaired immediately it should be covered or sealed carefully 5 Only the clean components can be installed 6 Do...

Page 107: ...ug please refer to Motorcycle Owner s Manual for the spark plug type and contact clearance Removal Installation and Maintenance of Ignition System Turn the key from to to open the ignition switch Turn...

Page 108: ...etween main cable and ECU Check the plug and replace it if necessary Note Don t charged inserted ECU controller For other checking please refer to 4 2 EFI System MAIN CABLE TO MAGNETO EXCITER COIL COU...

Page 109: ...the controller Ignition Coil Short circuit Engine is hard to start Engine lacks power Unstable idle speed Replace the ignition coil Broken circuit i e resistance is Engine fails to start Replace the...

Page 110: ...sensor water temperature sensor fan ECU EFI main relay and so on Removal Installation and Maintenance of Signal System Turn the key from to to open the ignition switch Turn the stop switch to to check...

Page 111: ...ar brake light and rear position light TAILLIGHT COUPLER OF RIGHT HANDLE BAR SW FRONT RIGHT WINKER METER TO MAIN CABLE COUPLER OF TAILLIGHT REAR WINKER TO MAIN CABLE COUPLER OF LED FRONT POSITION LIGH...

Page 112: ...f the bulb has broken disassemble the winker and replace the bulb with a new same type one MOUNTING SCREW OF WINKER HOUSING TURN SIGNAL BULB Checking method of front and rear winker are the same COUPL...

Page 113: ...float changes between F to E point fuel gauge LCD indicates 1 to 5 When the gear switch is set to a gear position and the gear line is connected to negative of battery and housing of engine the gear i...

Page 114: ...ulative mileage ODO 6 numbers maximum 99999 9 3 Temporary accumulative mileage TRIP 6 numbers maximum 99999 9 4 Gear indicating 1 6 gears 5 Fuel gauge 5 level the lowest level flashes when fuel starva...

Page 115: ...f cylinder head is above 92 the fan runs if it is below 89 the fan stops to run WATER TEMPERATURE SENSOR SPEED SENSOR FAN COUPLER OF FAN TO MAIN CABLE COUPLER OF MAIN CABLE TO WATER TEMPERATURE SENSOR...

Page 116: ...lace the horn switch Horn Inner wire is broken or damaged The horn is out of work or has abnormal sound Replace the horn Gear switch Poor connection of gear switch when gear shifting The gear indicato...

Page 117: ...t license plate lamp and so on Removal Installation and Maintenance of Lighting System Turn the key from to to open the ignition switch Check the signal system RIGHT HANDLE BAR SW LIGHTING SW IGNITION...

Page 118: ...PLATE LIGHT HOUSING BULB OF LICENSE PLATE COUPLER OF MAIN CABLE TO IGNITION S COUPLER OF LEFT HANDLE BAR SW HEADLIGHT TO MAIN CABLE COUPLER OF RIGHT HANDLE BAR SW TO MAIN CABLE COUPLER OF IGNITION SW...

Page 119: ...Check the couplers of left right handle bar switch to headlight Replace the coupler if there s short circuit broken circuit or poor contact If necessary disassemble the license plate light to check th...

Page 120: ...ch gear switch diode grounded cable battery fuse etc Removal Installation and Maintenance of Electric Starting System Turn the key from to to open the ignition switch Turn the stop switch to to check...

Page 121: ...for electric starting when engine is in neutral it can be electric started when engine is not in neutral it can be electric started by grasping the clutch lever The clutch switch is on Troubleshootin...

Page 122: ...e relay All switches Damaged or poor connection inside Motorcycle fails to start Replace the damaged switch Diode Diode is damaged or broken circuit Motorcycle fails to start Replace the diode Diode i...

Page 123: ...not used for a long time because it will self discharge and cause insufficient capacity The battery capacity will also decline after using for 2 3 years The voltage can be recovered by charging in thi...

Page 124: ...e the fuse and check it for tightness 3 If the fuse burns out repeatedly there is probably a overload circuit or short circuit The problem must be located and remedy it 4 Replace a fuse of the same ra...

Page 125: ...llow a electric circuit and a horn inside 1 Check the electric circuit When the horn is out of work first check the fuse then check the circuits of horn If above mentioned parts are good it means that...

Page 126: ...s After checking tighten up the rear axle nut Tightening torque of rear axle nut 70 90N m 5 1 3 Maintenance of Fuse System 5 1 3 1 Fuel system schematic of National stage 1 Turn off the fuel cock remo...

Page 127: ...ine is hard or fails to start Engine lacks power Idle speed is unstable Clean the fuel cock Fuel cock is damaged or clogged No fuel supply Engine fails to start Replace the fuel cock 5 1 4 Clean and I...

Page 128: ...engine suspension axle 24 30N m Nut of rear fork shaft 70 90N m Tighten the fasteners such as ones of upper connecting plate front rear wheel engine etc to specified torque s by means of torque wrenc...

Page 129: ...g in all steering positions Adjust or replace it if necessary 7 Lights and horn Check that headlights tail stop light winkers parting light indicators and horn function properly 8 Drive chain Check co...

Page 130: ...retor choke Air cleaner element Note C C C Spark plug Valve gap Engine oil Yearly R Every 2 000kmR Strainer of lubricant Yearly R C Tension degree of cam chain A A A A Engine idle speed Drive chain L...

Page 131: ...der 3 Remove the drive chain clean and oil it 4 Lubricate all of the controlling cables 5 Cover the motorcycle well Do not cover with plastic cloth or cloth with coating Store the motorcycle in a plac...

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