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LJ1P37QMB(3B3)

4- STROKE 50cc

SERVICE MANUAL

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Содержание LJ1P37QMB(3B3)

Страница 1: ...LJ1P37QMB 3B3 4 STROKE 50cc SERVICE MANUAL LCJNG JIA...

Страница 2: ...TENANCE INFORMATION 2 LUBRICATION SYSTEM 3 ELECTRONICALLY CONTROLLED CARBURETOR SYSTEM 4 REMOVAL ENGINE 5 CYLINDER HEAD VALVE 6 CYLINDER PISTON 7 V BELT DRIVING SYSTEM KICK START SYSTEM 8 FINAL DRIVIN...

Страница 3: ...m Transmission C V T Number Arrang ement Single Cylinder Max HP 25km h 2 3 kw 6500rpm Displacement 49 46 cc 45km h 3 0 kw 8000rpm Compression Ratio 12 0 2 1 Max Torque 25km h 3 5N m 6000 rpm Idle spee...

Страница 4: ...filling bolt 1 8 10 15 Oil pump flat screw 2 6 8 12 Left crankcase cover bolts 10 6 8 12 Camshaft chain tensioner pivot 1 6 8 12 Hex socket bolt Camshaft chain adjuster bolts 2 6 10 14 Cooling fan bol...

Страница 5: ...OPERATION Specification Fuel Tank Capacity 6 2L Engine Oil capacity 800 c c change 700 c c Transmission Gear oil capacity 140 c c change 120 c c Clearance of throttle valve 2 6 mm Spark plug CR6HSA Ga...

Страница 6: ...ing replaced if necessary L Lubrication Have your motorcycle checked adjusted and recorded maintenance data periodically by your LLL Authorized Dealer to maintain the motorcycle at the optimum conditi...

Страница 7: ...y 800cc Change 700cc When checking for oil leak run the engine at idle speed for a few minutes then check oil capacity with dipstick Cleaning the oil strainer Drain oil from engine remove the strainer...

Страница 8: ...ed quantity from the engine oil filling hole Install the oil filling bolt Torque value 10 15 N m Transmission oil capacity 140 c c 120 c c for change Recommended API GL 4 gear oil SAE 80W 90 AIR CLEAN...

Страница 9: ...with feeler gauge Valve clearance IN EX 0 05 0 02 mm 0 10 0 02 mm Loosen fixing nut and turn the adjustment nut for adjustment Caution CARBURETOR IDLE SPEED ADJUSTMENT Caution Checks and adjustment m...

Страница 10: ...htly accelerate the throttle valve and release it immediately Repeat this for 2 3 times 5 Read engine RPM and value on the exhaust analyzer Repeat step 2 to step 4 procedures until measured value with...

Страница 11: ...mbustion chamber or piston head DRIVING SYSTEM DRIVING BELT Remove left side cover Remove mounting bolt located under air cleaner Remove 9 bolts of the engine left crankcase Remove the left crankcase...

Страница 12: ...low by over flow pipe Replacement for every 1000km 1 Open the stopper 2 Drain the oil 3 Install the stopper Remove dipstick to check the oil level If oil level is below the lower limit mark add oil to...

Страница 13: ...OUBLESHOOTING 3 2 ENGINE OIL 3 3 CLEANING ENGINE OIL STRAINER 3 3 OIL PUMP 3 4 GEAR OIL 3 6 OIL FLOW DIAGRAM Valve rocker arm Camshaft Scoop lubrication Forcedly lubrication Forcedly lubrication Inner...

Страница 14: ...ump Inner rotor clearance 0 12 Clearance between outer rotor and body 0 12 Clearance between rotor side and body 0 05 0 10 0 20 Torque value Engine oil drain plug 20 26N m Engine oil filter screen cap...

Страница 15: ...ten it Torque value 20 26 N m CLEANING ENGINE OIL STRAINER Remove the oil strainer cap Remove oil strainer and spring Clean oil strainer recommended using compressed air to clean dirty foreign Check i...

Страница 16: ...engine right crankcase cover Make sure that the pump axle can be rotated freely Remove the oil pump driving gear nut Remove the oil pump Oil Pump Inspection Check the clearance between oil pump body...

Страница 17: ...into the pump body Align the indent on driving shaft with that of inner rotor Install the driving shaft Install the oil pump cover and fixing pin properly and then tighten screw 1 screw Oil Pump Insta...

Страница 18: ...vel too low Standard quantity 140 cc Replacement 120 cc Gear Oil Replacement Remove the gear oil filling bolt and its draining plug and then drain oil completely Install the draining plug and tighten...

Страница 19: ...URETOR SYSTEM 4 1 ECS illustration 4 1 Precautions in operation 4 2 General Information 4 3 ECS ILLUSTRATION LDNa J_LA Bectronically controlled c arbure tor tDutyfactor solenoid valve catalyst Oxygen...

Страница 20: ...andle free play 2 6 mm Cautions General Information Do not bend or twist throttle valve cable Damaged cable will make unstable driveability When disassembling fuel system parts pay attention to O ring...

Страница 21: ...e fuel pipe vacuum hose Disconnect auto by starter connector Disconnect gulp valve connectors Disconnect TPS controller connector Release the clamp strip of air cleaner Release the clamp strip of carb...

Страница 22: ...5 REMOVAL OF ENGINE MECHANISM DIAGRAM 5 1 OPERATIONAL PRECAUTIONS 5 2 MECHANISM DIAGRAM 3 5 4 5kgf m 4 5 5 5kgf m 4 5 5 5kgf m 2 4 3 0kgf m 4 5 5 5 kgf m 5 1 11 o _ _ _...

Страница 23: ...riving belt clutch and transporting disk 3 Final reduction gear mechanism Specification Specification Engine Oil Capacity Disassemble 800 c c Replacement 700 c c Gear Oil Capacity Disassemble 140 c c...

Страница 24: ...7 TROUBLESHOOTING 6 2 CYLINDER HEAD REASSEMBLY 6 8 CYLINDER HEAD REMOVAL 6 3 CYLINDER HEAD INSTALLATION 6 9 CAMSHAFT REMOVAL 6 5 VALVE CLEARANCE ADJUSTMENT 6 10 COMPONENT STRUCTURE 6 1 8 12 N m 8 12 N...

Страница 25: ...arm 10 000 10 015 10 10 arm OD of valve rocker arm shaft 9 972 9 987 9 90 OD of valve stem Intake 4 970 4 98 4 90 Exhaust 4 955 4 97 4 90 ID of Guide 5 000 5 012 5 030 Valve Clearance between Intake...

Страница 26: ...e from the cylinder head Remove the cylinder head cover 4 Cat nut and then remove the cylinder head cover Loosen the bolt of camshaft chain adjuster in a counter clockwise motion for release adjuster...

Страница 27: ...crankcase so that the hole on the camshaft sprocket is forward up and piston is at TDC position Remove camshaft sprocket bolt bolt Remove the cam sprocket and cam chain Removed the bolts of the left s...

Страница 28: ...emove cylinder head Caution Loosen the nuts diagonally by 2 3 sequences CAMSHAFT REMOVAL Remove the fixed bolt 1 then remove the camshaft Remove the valve rocker arm shaft Remove the valve rocker arm...

Страница 29: ...valve spring retainer valve oil seal Clean carbon deposits in combustion chamber Clean residues and foreign materials on cylinder head matching surface Caution Do not damage the matching surface of cy...

Страница 30: ...the clearance between the rocker arm shaft and the rocker arm Service Limit Replace when it is above 0 10 mm CYLINDER HEAD INSPECTION Check if spark plug and valve holes are crack Measure cylinder he...

Страница 31: ...e guide inner diameters Service limit 5 030mm The difference that the inner diameter of valve guide deducts the outer diameter of valve stem is the clearance between the valve stem and valve guide Ser...

Страница 32: ...so that can prevent from valve damaged CYLINDER HEAD INSTALLATION Install the lock pins and new cylinder head gasket onto the cylinder head Install the camshaft chain plate At first tighten the 4 nut...

Страница 33: ...in onto the cam sprocket Tighten the bolts of the cam sprocket Install the cylinder head side cover Torque value 20 25 N m Turn the cam chain adjuster in clockwise motion so that the adjuster is pushe...

Страница 34: ...UCTURE 7 1 GENERAL INFORMATION 7 2 TROUBLESHOOTING 7 2 CYLINDER REMOVAL 7 3 PISTON REMOVAL 7 5 PISTON RING INSTALLATION 7 7 PISTON INSTALLATION 7 8 CYLINDER INSTALLATION 7 8 COMPONENT STRUCTURE 8 12 N...

Страница 35: ...rt Clearance between piston and cylinder 0 025 0 035 0 100 ID of piston pin hole 10 004 10 010 10 040 OD of piston pin 9 994 9 998 9 980 Clearance between piston and piston pin 0 006 0 016 0 02 ID of...

Страница 36: ...r head refer to chapter 6 Remove 2 bolts and then take out the cam chain auto adjuster Remove cam chain plate Remove cylinder Remove cylinder gasket and lock pins Clean the residues attached onto the...

Страница 37: ...n the cylinder Service limit 39 05mm Calculate both the real roundness the difference between X and Y motion values and the cylindrical roundness the difference in the top center or bottom positions o...

Страница 38: ...in piston ring grooves Install the piston rings and then measure clearance between piston ring and its grooves Service Limit Top ring replace if over 0 09mm 2nd ring replace if over 0 09mm Take out th...

Страница 39: ...r diameter of piston pin hole Service Limit 10 040mm Calculate clearance between piston pin and its hole Service Limit 0 02mm Measure piston outer diameter Caution Service limit 36 920mm Compare measu...

Страница 40: ...lace the openings of piston ring as diagram shown Caution Do not damage piston and piston rings as installation All marks on the piston rings must be forwarded to up side Make sure that all piston rin...

Страница 41: ...ling piston into cylinder Press piston rings in one by one as installation Caution Install the cam chain plate the cylinder head gasket and lock pins Install cylinder head refer to Chapter 6 Install t...

Страница 42: ...PONENT STRUCTURE 8 1 GENERAL INFORMATION 8 2 TROUBLESHOOTING 8 2 LEFT CRANKCASE COVER 8 3 KICK STARTER ARM 8 3 DRIVING BELT 8 4 SLIDING PULLEY 8 6 CLUTCH DRIVEN PULLEY 8 9 COMPONENT STRUCTURE 55 65 N...

Страница 43: ...33 940 ID of sliding pulley 34 000 34 025 34 060 ID Inner Diameter OD Outer diameter Torque value Sliding pulley nut 40 50N m Clutch outer nut 50 60N m driving pulley nut 35 45N m Special Service Too...

Страница 44: ...cover plate on the left crankcase cover bolts 6 Remove left side cover plate gasket First put kick starter pedal into the starter shaft After a little rotation remove the drive gear and washer Removed...

Страница 45: ...hown Install kick starter arm temporary Rotate the lever and then align driving gear with width tooth on the starter shaft Install thrust washer and socket onto starter shaft Installation of the left...

Страница 46: ...e driven belt and clutch at same time Inspection Check the driving belt for crack or wear Replace it if necessary Measure the width of driving belt as diagram shown Replace the driving belt if it exce...

Страница 47: ...ter Install the clutch with universal fixture and then tighten nut to specified torque value Torque value 35 45 N m Caution Pull out driving pulley and then insert the driving belt into the driving pu...

Страница 48: ...Remove driving pulley Remove the sliding pulley fixing nut and remove the driving belt from the sliding pulley Remove the driving belt from the sliding pulley Remove the limited speed bush Remove the...

Страница 49: ...ear out or damage Replace it if necessary Measure each rollers outer diameter Replace it if exceed the service limit Service limit 15 57 mm Measure the inner diameter of the sliding pulley Service lim...

Страница 50: ...washer and nut Caution Hold driving pulley with universal fixture Tighten nut to specified torque Torque value 55 65 N m Install left crankcase cover The pulley surface has to be free of grease Clean...

Страница 51: ...pring compressor and remove clutch and spring from driven pulley Remove socket from driven pulley Remove oil seal from driven pulley Remove guide pin guide pin roller and sliding pulley and then remov...

Страница 52: ...re the outer diameter of driven face and the inner diameter of movable driven face Replace it if exceeds service limit Service limit Outer diameter 33 94mm Inner diameter 34 06mm Driven Pulley Bearing...

Страница 53: ...ary Apply with grease onto setting pins Apply with grease onto setting pins But the clutch block should not be greased If so replace it Install new clutch block onto setting pin and then push to speci...

Страница 54: ...all a new inner bearing Caution Align oil seal lip with bearing and then install the new oil seal if necessary Its sealing end should be forwarded to outside as bearing installation Install needle bea...

Страница 55: ...g and clutch into clutch spring compressor and press down the assembly by turning manual lever until mounting nut that can be installed Hold the compressor by bench vise and tighten the mounting nut t...

Страница 56: ...TURE 9 1 GENERAL INFORMATION 9 2 TROUBLESHOOTING 9 2 DISASSEMBLY OF FINAL DRIVING SYSTEM 9 3 INSPECTION OF FINAL DRIVING MECHANISM 9 3 BEARING REPLACEMENT 9 4 RE ASSEMBLY OF FINAL DRIVING MECHANISM 9...

Страница 57: ...er Outer type bearing puller Gear box oil seal installer Gear box bearing installer Torque value Gear box cover 20 25 N m Gear oil drain plug 10 15 N m Gear oil filling bolt 10 15 N m TROUBLESHOOTING...

Страница 58: ...bolts 7bolts and then remove the cover and the final driving shaft Remove gasket and setting pin Remove countershaft and gear Remove final driving gear and shaft INSPECTION OF FINAL DRIVING SYSTEM Che...

Страница 59: ...eal for wear or damage and replace it if necessary Check driving shaft and gear for wear or damage BEARING REPLACEMENT Caution Remove driving shaft bearing from left crankcase using following tools In...

Страница 60: ...ng puller Bearing protector Install a new driving shaft bearing onto crankcase Then install the driving shaft Specified tool Press the bearing in with C type hydraulic presser or bearing installer Ins...

Страница 61: ...il seal lip of final driving shaft Install the gear box cover and 7 bolts tighten the bolts Torque 20 25 N m Install the clutch sliding driving pulley Install the driving pulley belt and left cranksha...

Страница 62: ...LLATION 10 4 FLY WHEEL INSTALLATION 10 4 COMPONENT STRUCTURE GENERAL INFORMATION Refer to chapter 5 Engine removal and installation Refer to chapter 1 The troubleshooting and inspection of A C generat...

Страница 63: ...ain out the engine oil Remove the exhaust muffler 2 bolts 2 nuts Remove the fan shroud 4 bolts Remove the fan 4 bolts Hold the flywheel with the universal fixture Remove the 10mm nut on the flywheel S...

Страница 64: ...the A C generator assembly Caution RIGHT CRANKCASE COVER REMOVAL Remove the right crankcase cover 9 bolts Remove setting pin and gasket Remove the gasket or foreign materials on the connection surface...

Страница 65: ...Install the coil set onto right crankcase cover 2 bolts Install pulse generator 2 bolts Torque 8 12N m Tie the wire harness hose onto the indent of crankcase Install A C generator connector and pulse...

Страница 66: ...tall the cooling fan 4 bolts Torque 08 12N m Install the cooling fan shroud 4 bolts Install the exhaust muffler 2 bolts 2 nuts Add some engine oil according the specified quantity Cool fan 4 bolts Coo...

Страница 67: ...CRANKSHAFT 11 1 COMPONENT STRUCTURE 11 1 GENERAL INFORMATION 11 2 TROUBLESHOOTING 11 2 DISASSEMBLY OF CRANKCASE 11 3 CRANKSHAFT INSPECTION 11 5 ASSEMBLY OF CRANKCASE 11 6 COMPONENT STRUCTURE 8 12 N m...

Страница 68: ...then the crankshaft set have to replaced Specification Unit mm Item Standard Limit Left right clearance of the big end of the connecting rod 0 100 0 350 0 550 Radial clearance of the big end of the co...

Страница 69: ...ankcase Drive the screw of the crankcase remover set into the crankcase and then separate the left and the right crankcases Remove the cam chain Caution Special Service Tools Crankcase remover set l N...

Страница 70: ...residues off the crankcase contact surface Caution Remove oil seal from the left crankcase l Do not damage contact surface of the crankcase l Soap the gasket residues into solvent and the residues wi...

Страница 71: ...l directions Service limit 0 05 mm Place the crankshaft onto a V block and measure run out of the crankshaft with dial gauge Service limit 0 10mm Bearing Inspection Rotate the bearing with fingers and...

Страница 72: ...ankcase gasket Install the right crankcase and tighten the crankcase bolts 2 bolts Torque value 8 12 N m Install the cam chain tensioner Install a new O ring onto the mounting bolt of the chain tensio...

Страница 73: ...7 Apply with some grease onto the oil seal lip and then install it onto the left crankcase Press fit the oil seal to specified position with the oil seal installer 25x37x6 Special service tools the o...

Страница 74: ...ral information Refer to chapter 5 Engine removal and installation Refer to chapter 10 The troubleshooting and inspection of A C generator Specification unit mm Item Standard Limit ID of startion driv...

Страница 75: ...sket Remove the nut TOOL Start clutch Universal fixture Caution The nut is left handed Remove Start clutch outer and Wheel starter Remove Start reduction gear shaft Remove start reduction gear The ins...

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