Service Manual for engine

KE150
LXFD0901-054

Chongqing Loncin Motor co.ltd. July 2021

0
 Foreword

There are more and more motorcycles getting onto market with each
passing day, and new structure and technologies are also adopted. For all
the Loncin users and service workers know well about the maintenance,
adjustment and repair for engine KE150, we made this service manual, we
hope which bring you more convenience when you need them.
All the data in this book including diagrams, performance and other
data are all the latest until it printed. The Loncin motor.co.ltd. reserves
the right for further revision without any notice in advance. Any part
in this book belongs to Loncin copyright, any person or company is unable
to re-print unless got Loncin writing authorization in advance.

1
 Content list

1、 Summary…………………………………………………3
2、 Maintenance…………………………………..………16
3、 Cooling system………………………………………26
4、 Lubrication system…………………………………37
5、 Cylinder head, body and air system……………42
6、 Clutch and gearshift system………………………67
7、 Magneto and starting clutch……………….……83
8、 Crankcase and transmission system………………93
9、 Crankshaft, balancing shaft and accessories of
crankcase………………103

2
 1

Summary

Rules for maintenance………………………….………4

Specification………………………………………….…5
Torque………………………………………………………9
Sealing and lubrication position……………………12

3
 Rules for maintenance

1. Please adopt the Loncin motor co.ltd. produced or suggested spare parts, lubricant
or other auxiliary materials when maintenance is necessary. In case materials were
adopted fail to meet Loncin standard, it may damage your motorcycle.

2. When maintenance is necessary, please adopt the tools, bolt, nut and screw in metric
standard, the ones out of metric standard such as imperial standard are not allowed.

3. When parts were replaced or re-assembled, please also replace their washer, o-ring,
split pin and locking piece.

4. Please fasten the bolt or nut with bigger diameter or inside, then fasten the rest
in alternative angle sequence, unless there is another specially stipulated sequence.

5. Wash up the removed parts by cleanser. Coat the moving surface with lubricant before
re-assembling.

6. When re-assembled, please check and confirm the correct re-assembly and proper
operation, turn, move and operate them for checking.

Specification for engine

4
Normal specification
Itenms Data
Type LX157MJ
Displacement 149.6ml
Cylinder numbers and 单缸四冲程°
strokes
Bore×Stroke 57.3×58mm
Combustion chamber type Unregular combustion chamber，capacity:9.2±
and capacity 0.2mL
Engine

Compression ratio 11.3：1

Valve mechanism Camshaft on the top
Air inlet valve Open（rising stroke of 1mm） ：10°BTDC
Close（rising stroke of 1mm） ：38°ABDC
Air exhaust valve Open（rising stroke of 1mm） ：38°BBDC
Close（rising stroke of 1mm） ：3°ATDC
Lubricating system Forced pressure + splashing
Cooling system Water cooling
Engine net weight 26.5kg
Clutch Multiple and wet layers
Gear box International 6 gears
Transmission system

Primary transmission 3.261（75/23）

ratio
End transmission ratio 1.153（41/13)
st nd
Gear transmission ratio 1 ：3.083 2 ：1.941
rd th
3 ：1.5 4 ：1.227
th th
5 ：1.042 6 ：0.923
Gearshift 1-0-2-3-4-5-6-1
Ignition system EFI
Electrical system

Starting system Electrical starting

Lighting system Battery
Specification for spark CR9E（NGK）
plug
Clearance of spark plug 0.6-0.7mm
Rectifier regulator Regulating of 3 phases and complete wave

Cooling system’s specification

Items Specification
Coolant capacity Heat radiator (With all 0.6 L
water passages)
Coolant features and top temperature at outlet Ethanol，115℃
port
Thermostat Initial temperature when 82℃±2℃

5
 opening
Temperature when 92℃±2℃
completely opened
Rising travel of valve ≥4mm

Specification for lubrication system

Unit：mm
Items Standard Limit
Oil capacity When oil replaced 1.1 L —
New engine or engine 1.3 L —
disassembled
Oil we suggest Engine oil we suggest： —
SG10W～40 —
API’s quality grade：SG or
higher（Round lable for
API service of energy
saving is not allowed）
JASO T903 Standard：MA
Viscosity：SAE10W～40
Flowing amount for oil pump Oil temperature of 80℃，Rotation speed of
1500r/min，oil capacity for pump 0.72L/min
Rotor of oil Clearance for ≤0.15 0.22
pump internal rotor

Specification for cylinder head/Valves

Unit:mm
Item Standard Limit
Pressure in cylinder of electrical starting —
Valve clearance Air inlet 0.13-0.19 —
Air exhaust 0.22-0.28 —
Camshaft Height of Air inlet 30.565-30.695 30.465
camshaft Air exhaust 30.065-30.185 29.965
Clearance between journal 0.02-0.054 0.08
and bracket

6
 Runout 0.02 0.03
Valve and its Rod diameter Air inlet 4.475-4.490 4.455
guiding tube of valve Air exhaust 4.465-4.480 4.445
Inner In/Exhaust 4.500-4.512 4.550
diameter of
valve
guiding tube
Clearance Air inlet 0.010-0.037 0.075
between Air exhaust 0.020-0.047 0.090
valve rod and
its guiding
tube
Width of In/Exhaust 0.9-1.1 1.5
valve base
Free length of valve spring In/Exhaust 37.5 35.6
Installation length of valve In/Exhaust 33.1 —
spring
Flatness of cylinder head 0.05 0.08

Specification for clutch and gearshift device

Unit：mm
Items Standard Limit

Free travel for clutch lever 10-20 —

Clutch Free length of spring 28.2-28.8 27.1

Thickness of friction 2.35-2.45 2.2

plate
Flatness of driven — 0.10
plate
Collar in clutch Inner diameter 17.000-17.018 17.031

Outer diameter 23.972-23.93 23.96

Outer diameter of main shaft in clutch’s 16.966-16.984 16.95

collar

Specification for magneto and starting clutch

Unit：mm
Items Standard Limit
Outer diameter of jacket of 42.195-42.208 30.855
starting plate gear’ shaft
Inner diameter for outer case 58.854-58.88 58.89
of starting clutch

7
Specification for case body and transmission system
Unit：mm
Items Standard Limit
Diameter of M5、M6 20.00-20.021 17.07
inner hole on C2、C4 22.02-22.033 22.08
gear C3 23.02-23.041 23.09
C1 18.02-18.033 18.08
Outer diameter C1 17.979-18.00 17.90
for shaft’s
Transmission jacket
mechanism Inner diameter C1 15.00-15.021 15.10
of shaft’s
jacket
Diameter for Matched with jacket 16.959-16.98 16.93
main shaft of M5
Diameter for Gear matched with 19.978-19.989 19.92
countershaft shaft’s jacket C2
Gear matched with 14.966-14.984 14.90
shaft’s jacket C 1
Clearance Matched with jacket 0.02-0.054 0.10
between gear of M5
and main &
countershaft
Clearance C2 0.02-0.054 0.10
between gear C1 0.02-0.054 0.10
and shaft’s
jacket
Clearance C2 0.02-0.062 0.10
between C1 0.016-0.055 0.10
shaft’s
jacket and main
& countershaft
Gearshift Diameter of fork shaft 9.966-9.984 9.91
fork and its Inner diameter of fork 10.00 -10.018 10.03
shaft Thickness of fork’s tip 4.93-5.00 4.90

Specification for crankshaft, piston, cylinder body and balancing shaft

Unit：mm
Items Standard Limit

8
Crankshaft Clearance at bigger end of 0.10-0.35 0.38
connecting rod
Radial clearance at bigger end 0.005-0.015 0.025
of connecting rod
Runout 0.03 0.05
Cylinder Cylinder bore 57.301-57.322 57.344
Roundness 0.004 0.006
Diameter of basic circle for piston 57.275-57.285 57.265
Diameter for pin’s hole 14.002-14.008 14.02
Piston, piston Diameter of piston pin 13.995-14.0 13.985
pin and piston Closing clearance 1st ring 0.1-0.3 0.45
rings of piston ring 2nd ring 0.2-0.4 0.6
Scratching ring 0.2-0.7 0.85
Clearance Clearance 0.02-0.06 0.09
between piston between 1st ring
ring and its and its groove
groove Clearance 0.02-0.06 0.09
between 2nd
ring and its
groove
Clearance for cylinder matching 0.025-0.047 0.60
Smaller end of connecting rod and its inner diameter 14.013-14.025 14.045
Matching clearance between connecting rod and its pin 0.013-0.030 0.05

9
 Torque

Standard torque
Fastening parts Torque N.m Fastening parts Torque N.m
5mm bolt and nut 5.2 5mm screw 4.2
6mm bolt and nut 10 6mm screw 9.0
8mm bolt and nut 22 6mm flange bolt（8mm head，small 10
flange）
10mm bolt and nut 34 6mm flange bolt（8mm head，big 12
flange）
12mm bolt and nut 54 6mm flange bolt（10mm head） and 12
nut
8mm flange bolt and nut 27
10mm flange bolt and nut 39

Torque for engine

Items Numbers Thread Torque N.m Note
diameter mm
Spark plug 1 10 14
Left decorative cover 1 30 10
View hole cover 1 14 5
Oil drainage bolt on 1 12 24
engine

Cooling system
Items Numbers Thread Torque N.m Note
diameter mm
Water drainage bolt 1 6 10
Bolt on cover of 2 6 10
thermostat
Bolt for water pump’s 3 6 10
chamber
Coolant temperature 1 12 15
sensor

10
Cylinder head and valves
Items Numbers Thread Torque N.m Note
diameter mm
Nut on cylinder head 4 8 30
Side bolt of cylinder 2 6 10
body
Bolt on camshaft’s 8 6 12 Coat the thread and
bracket surface of base with
oil, and the fastening
way is in the following
chapter
Bolt on cylinder head 4 6 10
cover
Tensioner bolt 2 6 10
Bolt on tensioner’s cap 1 6 4
Noiseless bolt (On the 1 6 10
left side of cylinder
head)

Clutch and gearshift device

Items Numbers Thread Torque N.m Note
diameter mm
Nut on clutch 1 14 74 Coat thread with oil
Bolt of clutch’s 4 6 12
spring
Nut on primary driving 1 14 74 Coat thread with oil
gear
Bolt on locating plate 2 6 10
of clutch drawing
cable
Bolt on right 7 6 10
crankcase cover
Bolt of five star 1 6 12 Coat thread with

11
shaped turning plate Loctite

Magneto and starting clutch

Items Numbers Thread Torque N.m Note
diameter mm
Fastening bolt for 3 8 29 Coat thread with sealing
starting clutch glue
Bolt on magneto’s rotor 1 12 64 Coat thread and base
surface with oil
Bolt on magneto’s stator 3 6 10 Coat thread with sealing
glue
Fixing bolt on trigger 2 6 10 Coat thread with sealing
glue
Bolt on left crankcase 9 6 10

Case body and transmission system

Items Numbers Thread Torque N.m Note
diameter mm
Limit plate for timing 2 6 12
chain
Bolt on pressing plate 2 6 10 Coat thread with
of adjustive plate sealing glue
Bolt for check plate 2 6 12 Coat thread with sealing
of main shaft’s glue

bearing
Side bolt of 10 6 10 Replace the bolt for a
combination for left new one as below:
case body Pre-fasten the case
combination bolts in
alternative angle
sequence, the fasten
to given torque in

12
 turn.
Side bolt of 4 6 10 Replace the bolt for a
combination for right new one as below:
case body Fasten by two steps in
crossing way.

Positions for lubrication and sealing

Engine
Material Position Note
Sealing 1596 Combination surface of crankcase
glue 1262 Thread fastening
The complete surface for inner and
outer rotor of oil pump
Rod end and sliding surface of valve
rod
Complete surface of timing chain
Rolling surface of camshaft
Inner surface of hole on cylinder
Oil in engine External surface of piston, hole of
piston pin and groove of piston ring
External surface of piston pin
Complete surface of piston ring
Complete surface of clutch’s friction
plate
External and internal surface for
clutch collar
Surface of internal hole on driven gear
Gearshift rod and turning plate
Complete surface for double gear’s
shaft
Complete surface for starting clutch
Complete surface for turning fork’s
shaft
Internal hole on smaller end of
connecting rod of crankshaft
Gear(Primary transmission, crankcase,
starting deceleration)

13
 Sliding surface of plate-shaped gear
Turning area of each bearing
Surface of each o-ring
Oil of molybdenum Swinging arm
disulfide Surface of camshaft
Hole on camshaft of cylinder head
Multi-functional Seal ring for starting motor
lubricant Seal ring for speed sensor
Seal ring for left decorative cover
Degreaser All surfaces for combination

Fastening for bolts on cylinder head

1. Coat the thread and contact surface of nut （M8×8.5） of 1-4 on cylinder head
with oil;
2. Fasten the bolt of 1-4 by sequence as pictures above shows to 5N·m;
3. Fasten the bolt of 1-4 by sequence as pictures above shows to 15N·m;
4. Fasten the bolt of 1-4 by sequence as pictures above shows to 30N·m；
14
 5. Fasten bolt 5-6（M6×115） to 10 N·m.

Fastening for bolt on bracket of camshaft

1. Coat all the contact surface and thread of bolt with oil:
2. Fasten the bolt of 1-8 by sequence as pictures above shows to 5 N·m；
3. Fasten the bolt of 1-8 by sequence as pictures above shows to 12 N·m；

15
Fastening for bolt on crankcase

1. Put all the bolts in place according to their depth of thread (The exposing part
of thread shall be about 10mm),
2. Fasten the bolts （M6×40、M6×65）1-10 on left crankcase according to the sequence
showing in picture below to 10 N·m;
3. As the bolts showing in picture above, the bolt 1, 2, 3, 4, 10 are the ones of M6
×65;
4. As the bolts showing in picture above, the bolt 5, 6, 7, 8, 9 are the ones of M6
×40.
5. Fasten the bolts 1-4 （M6×35、M6×65）on right crankcase according to sequence
in picture to 10 N·m;
6. As the bolts showing in picture above, the bolt 1 and 4 are the ones of M6×65.
7. As the bolts showing in picture above, the bolt 2 and 3 are the ones of M6×35.

16
 2
Maintenance
Information of maintenance………………………………17
Specification of maintenance…………………….………17
Breathing tube of crankcase………………………………18
Spark plug…………………………………………………19
Valve clearance……………………………………………19
Oil in engine…………………………….…………………23
Engine idling…………………………….…………………24
Clutch………………………………………………………24

17
 Information of maintenance
Summary
 Please put the motorcycle on a horizontal ground before all operations latter.

Tools

Socket wrench for spark plug

Specification for maintenance

Please inspect according to <Periodic Maintenance table> in User Manual.
In order to keep good power performance and economic working, the maintenance below
is necessary.
Start from 36000km or the 36th month，repeat the maintenance with interval of 12000km
or 12 months.
I: Inspection, clean it up, adjust, lubricate or replace when it was necessary. C:
Clean up. A: Adjust. L: Lubricate.

The maintenance below need you know something about machinery. Some items (Especially

with mark *), they may need more skill or tools and information.

Periodic Maintenance table

Ref.No Interva X1000km 1 6 12 18 24 30 36
l
Month 1 6 12 18 24 30 36
Items
*1 Spark plug R R R
*2 Oil in engine R R R R R R R
*3 Oil filtering
C C C
screen
*4 Valve
Each 42000km，I
clearance
*5 Coolant I I I I R I I
*6 Cooling system I I I I I I
*7 Fuel tube I I I I I I
8 Breathing tube C C C C C C
18
 of crankcase
9 Clutch system I I I I I I I
10 Driving
sprocket wheel I R I R I R
of countershaft

Caution：
1. More frequent maintenance is necessary in case driving under dusty or wet conditions
2. Driving in rain or under full speed, the more maintenances are needed.
3. The mileage and working time, who was reached first then start the maintenance.
4. *Means special tools, data and specialized skill is needed, which shall be done
by Loncin dealer.

Breathing tube on crankcase

Caution：
 When driving in rain or under full
speed, when washed or oppositely put
the motorcycle, the more maintenance
is needed. Check the sediment in
breathing tube by viewing its
transparent part. [1]
Pull off the plug [1] of cleaning tube
on air filter, then drain off the
sediment into suitable container and
re-assemble the plug.

Remove the fuel tank and hold it on.

Check the crack, aging, damage or
flexibility on cleaning tube [1] of air
filter, replace if it is necessary.
Re-assemble the fuel tank.

[1]

19
 Spark plug
Remove the fuel tank and surrounding parts. Fastening torque：14N·m
Remove the spark plug[1]. Re-assemble the fuel tank and the parts
Caution： surrounding.
Before removing the spark plug, blow and wash
its surroundings of base by air gun and make
sure there is not any dust drops into the
combustion chamber. Check and confirm the [1]
damage or crack on insulators, also check the
damage, dirt or color fading on terminal, please
replace the spark plug in case it is necessary.

Check the spark plug：

Wash the terminal of spark plug by iron wire
or the washer for it only.

Check the clearance between the central and

side terminals by feeler gauge.
Clearance of spark plug：0.60-0.70mm
Carefully get the side terminal bent to adjust
the valve clearance if it is needed.
Install the fasten the spark plug to cylinder
head by hand, then fasten the spark plug to
fixed torque.

Valve clearance
Check

注意：
Note：
— Please check and adjust the valve
clearance when the engine is cold
(Under 35℃)
[2]
Please remove the parts below:
— Cylinder head cover
— Left decorative cover and its o-ring
— View-hole’s cover and its o-ring.
Assembly: Turn the crankshaft anti-clockwise
by socket wrench of 17mm, get mark “T” [1] on [1]
magnetic cylinder aligned with the indicating
scale line [2] on left front cover.
20
Make sure the timing marks (IN and EX) on convenient for disassembly or re-assembly.
sprocket wheel get aligned with the surface of Round point
cylinder head, ensure the punching mark of faces
round point face upward. upwards
(As picture shows) In case the timing marks are
not at the demanded position, turn the
crankshaft anti-clockwise by 360
Caution：
 When the engine is under this condition,
“EX” “IN”
it’s the timing condition, at the upper
stopping point of cylinder, the 2 tips of cam
didn’t touch the swinging arm, which is
Alignment for timing: Turn the crankshaft
anti-clockwise, until the scale line |T on
magneto gets aligned with timing gap on Valve clearance：
edge of view-hole’s cap at left, meanwhile IN：0.16±0.03mm
the scale mark IN on end surface of driven EX：0.25±0.03mm
sprocket wheel of air inlet shaft and scale Caution：
mark EX on that of air exhaust get parallel  Take record for each valve clearance to get
to installation surface of cylinder head. reference for selection of shims when
Insert the feeler gauge between swinging arm adjustment was needed.
and cam of air inlet and exhaust to check the
valve clearance.

Adjustment

Caution：
 Adjustment for valve clearance needs to remove
the swinging arm shaft.
 Adjust the engine to condition
of installation as former chapter
shows.

21
 [2]

[1]

Operate as below：
— Remove bolt [1] of tensioner and seal
ring[2]，
— Insert a single sheet into tensioner.
— Get back clockwise to tensioner [3].
[3]

Remove the parts below:

— Screw on swinging arm and its shim [1]
— Swinging arm shaft [2] of valve.
Caution： [1]
 To avoid the damage on swinging arm shaft
of valve, please confirm the engine is at the
timing position, then slightly turn the bolt
into shaft and slightly take out.
[2]

Operate as below:  Remove the shims by magnet or tweezers

— [Move the swinging arm [1] of valve may let your work easier.
outwards
— Remove the shims [2] by magnet bar
tweezers may let your work easier.

[2]
Caution：
 Avoid the shim drop into crankcase and
spark plug’s hole.
 Mark up all the shims to make sure their
correct re-assembly. [1]

22
 Measure the thickness of shim [1] and take
record.
Note:
 There are 69 different thickness of
shims are selectable with difference of
0.025mm between each adjuscent two
(1.200～2.900mm)
 Calculate the thickness of new shim by
equations below:
A=(B-C)+D
A: Thickness of new shim
B: Take record for valve clearance
C: The stipulated valve clearance
D: Thickness of removed shim
Adopt micrometer to ensure the
thickness of shim.

Coat the end part of valve rod with oil.

Re-assemble the new shim [1] to the valve
spring’s base.
[2]
Coat the sliding area, thrust surface and
external surface of swinging arm’s shaft with oil.
Fix the swinging arm, then insert its shaft [2]
into cylinder head and the arm itself.
Coat the threaded part of bolt of swinging
arm’s shaft with oil, and replace the washer [3] [3]
for a new one.
[1]

Fasten the bolt to stipulated torque. view-hole’s cap.

Fastening torque：13N·m Coat the threaded part of view-hole’s cap
Loosen the single sheet to let the tensioner with lubricant and re-assemble the cap.
recover to its normal condition, then install the Fasten the view-hole’s cap to given torque.
bolt and seal ring for tensioner. Fastening torque：5N·m
Turn the camshaft several times by turn the
crankshaft clockwise. The way for re-assembling the cylinder head
Measure the valve clearance once again. cover please refer to Chapter 5th.
Replace the o-ring for a new one and coat it
with oil, then install it into the groove on

23
 Oil in engine
Check the residual oil in engine
Start and idly run the engine for 3~5 minutes.
Stop the engine and wait for 2~3 minutes.
Lay the motorcycle on horizontal ground and
make it upright.
Check the residual oil by the oil gauge [2].
Insert the oil gauge into its hole, in case the oil
level is lower than the lowest line {1}, please fill
[2]
up to highest level line [3], in case the level is
higher than line [3], suck some by suction [3]
nozzle back to highest line [3].
Appointed oil：For Loncin only
[1]
API grade of quality: SG or higher(Adopt the
one with round service label of API whose mark
is energy saving is not allowed.）
JASO T903 standard：MA
Specification:
SAE10W-30,10W-40,10W-50,15W-40, 20W-40,
20W-50。
Check the normal performance of o-ring on oil
plug, replace if it is necessary.。
Coat the o-ring with oil.
Re-assemble the oil plug.

[1]

Replacement for oil

Stop the engine and remove oil gauge [1].
Remove the oil drainage bolt [2] and washer [3],
then drain off the oil.
When the oil drained off, re-assemble the
drainage bolt [2] and replace the washer for a
new one.
Fasten the oil drainage bolt to given torque.
Fastening torque: 24·m
[3]
Fill up the oil to upper scale mark.
When drained off：1.1L [2]
New engine or after broke up：1.3L
Check the oil level.
Make sure there is not any oil leakage.

24
 Engine idling
Caution：
 When finish all the maintenance items and confirmed they meet demands, then
check the idling.
 Check the items before inspecting the idling:

- The malfunction indicating light didn’t flash

- The normal performance of spark plug
- The normal work of element of air filter
- The free travel of throttle switch and throttle lever
The idling could be checked and adjusted when the engine is hot only.
Start the engine to let it get to normal working temperature, then make it idly run.
Check the idling.
Idling speed: 1500±100

In case the idling speed is out of limited range, please check the parts below:
— The problem of air inlet amount or engine’s end
— Operation of controlling valve for idling
— Wire, circuit and each connector

Clutch

Check the distortion or damage or clutch

cable, then lubricate the clutch cable when it is
necessary.
Check the free travel of clutch lever at its end
part.
Free travel：10-20mm

Adjustment in a small range could be done by

the adjustor on clutch lever.’
Loosen the locking nut [1], turn the adjustor
according to your demand.
Hold the adjustor, meanwhile fasten the locking
nut.
When you passed the wire limit of adjustor, the
precise free travel could not be got, at this
moment, we need the main adjustor.

25
Adjust the main adjustor by turn its nut [1] on
operation arm of clutch.
Loosen the locking nut [2], turn the adjustor
according to your demand.
Hold the adjustor meanwhile fasten the locking
nut.
In case the correct clutch travel failed to be got,
or it gets skidding when making trial driving,
please break down and check the clutch.

[2]
[1]

26
 3
Cooling system
Information for maintenance……………………….………27
Specification for cooling system…………………………27
Troubleshooting……………………………………….………28
Mode for system procedure………………….………………29
Test for system………………………………………….……30
Replacement for coolant………………….…………………31
Thermostat………………………………………………………32
Cooling pump……………………………………………………34

27
 Information for maintenance

Summary

△Warning
！

Please don’t remove the cover of heat radiator when the engine and
radiator completely cooled down, otherwise the coolant may inject or
splash out and get your injured.

Caution：
The coolant with silicate solvent of anti-corrosion may accelerate the wear-out of
seal ring on water pump and block up the passage of heat radiator.
Use the running water may damage the engine
 Fill up the sub tank with coolant, except filling up of draining off, please don’t

28
 remove the cover of heat radiator.
 The engine needn’t be removed from frame when maintaining the cooling system.
 The coolant touches the painting surface is not allowed.
 Check by coolant temperature indicator/Water temperature sensor.
 Check the relay of cooling fan’s controller.

Specification of cooling system

Items Specification
Coolant capacity Heat radiator (With all 0.6 L
water passages)
Coolant features and top temperature at outlet Ethanol，115℃
port
Thermostat Initial opening 82℃±2℃
temperature
Completely opened 92℃±2℃
temperature
Rising of valve ≥4mm
Coolant we suggest Coolant with ethanol but without silicate

Troubleshooting

Too high the engine temperature

 Malfunction in coolant temperature indicator/Water temperature sensor
 The thermal valve failed to be opened
 Malfunction on heat radiator’s cover
 Coolant is not enough
 Passage, soft hose and water tube of heat radiator blocked up
 Air got into circulation system
 Malfunction in motor of cooling fan
 Malfunction in relay of cooling fan’s controller
 Malfunction in water pump

Too low the engine temperature

29
 Malfunction in coolant temperature indicator/Water temperature sensor
 The thermal valve was opened
 Malfunction in relay of cooling fan’s controller

Coolant leakage
 Defect on machinery structure of water pump
 O-ring gets aged
 Malfunction on cover of heat radiator
 Gasket of cylinder head gets damaged or aged
 The joint of soft hose or tube clamp get loose
 Soft hose gets damaged or aged
 Heat radiator gets broken
 The cover of thermostat or tube joint of water pump’s cover is flexible.

30
 Mode of system procedure

出水管

节温器

进水管

水泵

散 热 器 ： Heat radiator 出 水 管 ： Water outlet tube 小 循 环 方 向 示 意 图 ： Figure for

sub-circulation 进水管：Water inlet tube 节温器：Thermostat 大循环方向示意图：Figure
for major-circulation 散热器冷却液入口：Inlet port for coolant of heat radiator 散
热器冷却液出口：Outlet port for coolant of heat radiator

31
 Test for system

Pressure test for cover of heat radiator/System

Remove the fairing of right middle
impeller
Remove the cover [1] of heat radiator

[1]

Get the gasket of cover of heat radiator their air tightness.

wet, then install the cover into tester
[2].
Lay the pressure on the cover by tester.
In case the cover failed to keep pressure
or too high or low the releasing pressure,
the cover need be replaced.
The cover must bear the stipulated
pressure at least by 6 seconds.
The pressure on heat radiator’s cover:
108 KPa
Connect the tester to heat radiator.
Lay the pressure on heat radiator, engine
and their soft hose by tester to check

Caution：
 Overpressure may damage the cooling system or its components. The pressure must
not be higher than 108 KPa.
 In case the system failed to bear the pressure at least by 6 seconds, please repair
32
 or replace the components.

Replacement for coolant

Coolant replacement/Air exhaust

Caution： ground and stay it upright.
When filling up coolant into sub tank ,
system, or check the coolant level,
please lay the motorcycle on horizontal
Remove the fairing of cooling fan. ﹒m
Remove the drainage bolt [1] and flat Drain off the coolant.
washer [2] of water pump.
Remove the cover [3] of heat radiator and
drain off the coolant.
Fastening torque:
Water drainage bolt on cooling pump:10N
[3]
[1]/[2]

Fill up the system with the recommended

coolant through the filling port until
reached its neck [1].
Recommended coolant:
With ethanol but without silicate

[1]

Exhaust the air in system by steps below:

1. Shift the engine to neutral gear.
Start the engine and let it idly run for 2-3 minutes.

33
2. Open and stop the throttle by 3-4 times to exhaust the air in system.
3. Stop the engine, fill up the coolant if it is necessary.
4. Install the cover of heat radiator.
Fill up the storage case by recommended coolant.
Re-assemble the fairing cover.

Thermostat

Disassembly/Re-assembly
Drain off the coolant.
Remove the thermostat from cooling water
tube.
Remove the bolt [1] and thermostat’s
cover [2].

[2]

The re-assembly is precisely opposite to

disassembly.
[1]
Fastening torque:
Face
Bolt on thermostat’s cover: 10N·m upwards

Caution：
 When re-assembling the thermostat,
make sure its air exhaust hole face
upwards to exhaust the air bubble in
coolant.

Check/Test
Check if there is damage on the surface of thermostat [1].
34
In case the thermal valve was open under
room temperature, which means it need be
[2] [1]
replaced.
Check the damage on seal ring [2], replace
if it is necessary.

Caution：
 Wear the oven gloves and suitably Suspend the thermostat [2] in hot water
protect your eyes. to check and confirm its normal
 Keep the combustible materials performance.
far away from electrical parts.
Don’t let the thermostat and
thermometer [1] touch the bottom
plate, otherwise the data you got may
be wrong.
Heat the water to working temperature by
electrothermal furnace and keep it for
5 minutes.

Initial opening temperature of thermostat:

80 -84℃
Height when the valve completely opened:
Under 90-94℃ no less than 4mm
In case the thermostat gets opened when the temperature was out of stipulation, please
replace it.

35
 Cooling pump

Check the sealing of end surface

Check the coolant leakage from overflow the water pump and right crankcase cover
hole [1] on water pump. set.
 Just a few coolant overflow means
it is normal.
 Make sure there is not coolant
keeps overflowing when engine
started.
In case it is necessary, please replace [1]

Disassembly/Re-assembly
The disassembly and re-assembly for cooling pump is as picture below:

定位销：Positioning pin 冷却泵齿轮：Gear for cooling system

冷却泵轴：Shaft for cooling system 平垫圈：Flat washer
右曲轴箱盖：Right crankcase cover 油封：Oil seal
动静环组合：Dynamic and static ring set
冷却泵叶轮组合：Impeller set for cooling system
冷却泵盖密封圈：Seal ring for cooling pump's cover
冷却泵盖：Cover for cooling pump 密封垫：Gasket 锁紧螺栓：Locking bolt

Disassembly
Caution：

36
  Lay a clean oil tray under engine, when removing the right crankcase cover,
there may have oil flow out. When re-assembled, fill up with recommended oil
to stipulated position (By referring the Maintenance Guidance).
Drain off the coolant
Lay the motorcycle on a horizontal ground and make it upright.

Loosen the tube clamp [1], then loosen

[2]
water inlet tube [2] on cooling system.

[1]

Remove the parts below：

- Bolt [1] on water pump’s cover [1]

- Water drainage bolt and washer [2]

- Cooling pump cover [3]

[3]

[2]

Check distortion and damage on seal ring

[2] of cooling pump’s cover, in case it
is, please replace.

37
 [1]

[2]

Remove the cooling pump set, going on without jamming.

Remove the right crankcase cover set,
[2]
Remove the impeller [1] and flat washer
[2] of cooling pump by turning [1]

anti-clockwise.
Turn the gear [3] of cooling pump to check
jamming.
Remove the gear and shaft [4] of cooling
pump, check distortion or damage on gear,
shaft, and impeller of cooling pump, in [3]

case there is, please replace. [4]

Caution：
 There is some resistance when
turning the gear of cooling pump
is normal, but it should keep

Check the distortion or damage on oil seal The re-assembly is precisely opposite to
[1] and dynamic & static ring [2] set, in disassembly.
case it is , please replace. Fastening torque:
38
Installation torque for impeller of
cooling pump: 10N·m
[1]

Check the oil amount.

[2]

4
Lubrication system
Information for maintenance………………….…………38
Specification for lubrication system…………………39
Troubleshooting…………………………………….………39
Diagram for lubrication sy………………………………40
Oil pump………………………………………………………41

39
 Information for maintenance

Summary

△Warning
！

Repeatedly touch the engine oil in long time may get skin cancer, but this
kind of situation is rarely to be seen, unless your skin touches the engine
oil every day, but we still you suggest you wash up your hands by soap
and clean water as soon as you deal with the replaced oil.

Caution:
 When repairing the oil pump, we needn’t remove the engine from frame.
 The pre-condition for all maintenance steps in this Chapter is drain off the
oil in engine.
 When disassembling and re-assembling the oil pump, please don’t let dust or
dirt get into engine.
 Any part in oil pump passed the limit for maintenance, please replace the oil
pump as a complete set.
 When the oil pump re-assembled, please check the oil leakage and correct oil
quality.

40
 Specification for lubrication system

Unit：mm
Items Standard Limit
Oil capacity Capacity（New engine 1.3L —
or breaking down）
Capacity（Only 1.1L —
replacement）
Recommended Brand Oil for Loncin only —
oil Specification SAE 10W-30,10W-40,10W-50, —
15W-40, 20W-40, 20W-50
API quality grade：SG or
Grade higher（Don’t adopt the
one with round label of API
service for energy saving）
JASO T903 standard：MA
Rotor of oil Clearance between ≤0.15 0.22
pump external and internal
rotors

Troubleshooting
Too low the oil level
 Too heavy the oil consumption
 Oil leakage on external components
 Piston ring worn out or without assembling in place
 Cylinder worn out
 Valve guiding tube worn out

Oil gets dirty

 Didn’t replace oil and filtering screen periodically
 Piston ring gets damaged

Oil emulsified
 Leakage on coolant passage
 Water gets into engine

41
 Diagram for lubrication system

机油泵：Oil pump 机油滤网：Oil screen 油底壳：Oil bottom case

Oil pump
Disassembly/Re-assembly
Remove the right crankcase cover set,
Remove the fastening bolt [1] and oil pump
[2]
[2].

[1]

The re-assembly is precisely opposite to hand to confirm without jamming.

disassembly.
Caution: Before re-assembly, turn the
gear of oil pump by more than 2 rounds by
Torque 机油滤网
Bolt on oil pump: 12N﹒m

Disassembly/Re-assembly
42
The disassembly and re-assembly for oil pump is shown as below:

油泵盖：Oil pump’s cover 定位销：Positioning pin 平垫圈：Flat washer 油泵座体：Oil

pump’s base body 油泵传动轴：Transmission shaft for oil pump 内转子：Internal rotor
外转子：External rotor 开口挡圈：Opening circlip 油泵从动轮：Driven gear of oil pump

Check: - External rotor

 Check the driving and driven gear - Base body of oil pump
of oil pump. Measure the oil pump clearance according
Check the damage, wear-out, distortion to specification of lubrication system.
and burn-out on parts below: Any measured result passed the
- Shaft of oil pump maintenance limit, please replace the
- Positioning pin complete oil pump set.
- Internal rotor

5
Cylinder head, body and air system
Information for maintenance……………………………………………………43
Specification for cylinder head/air valve/piston/cylinder body….…44
Troubleshooting……………………………………………..……………………45
Components position…………………………………..…………………………47
Compression test for cylinder……………………..…………………………48
Cylinder head cover……………………………………………………….…………49
Tensioner………………………………………………………………….…………50
Camshaft…………………………………………………………….………………51
Swinging arm……………………………………………..…………………………55

43
Cylinder head……………………………………………..………………………56
Timing chain/Sprocket wheel………………………………….……………………60
Cylinder body/ Piston………………………………………………….……………61
Stud/ Pin pressor………………………………………………..…………………64

Information for maintenance

Summary
 This chapter includes the inspection and maintenance for cylinder head, body, valve,
camshaft, swinging arm, piston and pin pressor.
 When repairing the cylinder head cover, camshaft, and tensioner, judge from the
shielding piece to decide if we need remove the engine from frame; But when
repairing the cylinder head, cylinder body, air valves, piston and pin pressor,
we need remove the engine from frame.
 When disassembling the components, mark up the removed parts for a correct
re-assembly.
 Before checking, wash up all the removed parts by cleanser, then dry them up by
compressed air.
 The lubricant on camshaft is got through the oil passage in cylinder head and
camshaft’s bracket, in this case, before re-assembling the cylinder head and
camshaft’s bracket, wash up their oil passage first.
 Please don’t damage the contact surface when disassembling the cylinder head,
its cover, and cylinder body.

Tool(s)

44
压缩表附件：Compression gauge’s accessory
气门弹簧压缩附件：Compression accessory for valve spring
气门弹簧压缩工具：Compression tool for valve spring

Specification for cylinder head, valves, piston and cylinder body

Unit：mm
Items Standard Limit
Cylinder pressure under electrical starting 1200-1400kPa/390r/min —
Valve clearance Air inlet 0.13-0.19 —
valve
Air exhaust 0.22-0.28 —
valve
Camshaft Protrusion Air inlet 32.565-30.695 32.465
height of Air exhaust 30.065-30.185 29.965
cam
Clearance between journal 0.02-0.054 —
and bracket
Runout 0.02 0.03
Valve and its Diameter of Air inlet 4.475-4.490 4.455
guiding tube valve rod Air exhaust 4.465-4.480 4.445
Internal Air 4.500-4.512 4.550
diameter of inlet/Exhaust
valve’s
guiding tube
45
 Clearance Air inlet 0.010-0.037 0.075
from valve Air exhaust 0.020-0.047 0.090
rod to
guiding tube
Width of Air 0.9-1.1 -
valve base inlet/Exhaust
Free length of valve spring Air 37.50 35.60
inlet/Exhaust
Installation length of Air 33.10 —
valve spring inlet/Exhaust
Flatness of cylinder head 0.05
Cylinder body Cylinder bore 57.301-57.322 57.344
Cylindricity 0.004 0.006
Diameter for base circle of 57.275-57.285 57.265
Piston, piston piston
pin and piston Diameter for pin’s hole 14.002-14.008 14.02
ring Diameter for piston 13.995-14.00 13.985
st
Closing 1 ring 0.10-0.30 0.50
nd
clearance for 2 ring 0.2-0.4 0.6
piston ring Oil ring 0.2-0.7 0.85
Clearance Clearance 0.02-0.06 0.09
st
between piston between 1
ring and its ring and its
groove groove
Clearance 0.02-0.06 0.09
nd
between 2
ring and its
groove
Cylinder matching clearance 0.025-0.047 0.06

Troubleshooting

 Malfunction at the top place of engine is usually bad for engine performance. We
can find out these malfunctions by compression test, also we can find them by
detective rod or stethoscope to know where the engine noise comes from
 In case the power output of engine is weak when it under low speed, please check
if there is white smoke in beathing tube of crankcase. In case the soft hose is
smoky, please check the jamming on piston ring.

When engine is working under low speed, too low the compressing pressure, difficult
starting or poor performance
 Valve
46
 — Incorrect adjustment for valve clearance
— Valve burned out or got bent
— Wrong valve timing
— The valve spring got cracked
 Cylinder head
— The gasket of cylinder head with leakage or damage
— Cylinder head gets bow, twist or crack
— Spark plug is flexible
 Cylinder, piston or piston ring worn out

Compressing overpressure, overheat or cylinder knock

 Too much carbon buildup on piston head or in combustion chamber

缸体过热或敲缸 Cylinder head overheated or knocking

 Too much carbon buildup on piston head or in combustion chamber

Smoky
 Cylinder head
— Valve rod or guiding tube worn out
— Sealing piece for valve rod damaged
— Cylinder, piston, or piston ring worn out

Noisy
Cylinder head
— Incorrect adjustment for valve clearance
— Valve gets jammed or its spring cracked
— Camshaft worn out or damaged
— Swinging arm and its shaft worn out
— Swinging arm and valve rod’s end worn out
— Camshaft got flexible or worn out
— Timing chain worn out
— Gear of cam’s sprocket wheel got worn out
 Cylinder, piston, and piston ring got worn out

Poor idling
 Too low the compressing pressure in cylinder

Too much waste gas

 Cylinder body, piston or piston ring got worn out
 Incorrect piston ring assembly
 Scratch on piston or cylinder wall

Abnormal noise of engine

47
 Piston pin and its hole worn out
 Cylinder body, piston or piston ring worn out
 Pin of crankshaft worn out

Components position

48
 Cylinder compression test

Start engine for several minutes to Compression gauge

pre-heat it.
Stop the engine and remove the spark plug.
Install the threaded end of cylinder
pressure gauge into the hole of spark
plug.
Tool:
Turn the ignition switch and engine switch to the position ON.
Turn the gear position to neutral.
Turn the throttle to top position and hold on, start engine until the data on pressure
gauge stopped rising.
The max. data may usually keep for 4-7 seconds.
Compressing pressure:
When 450rpm，it is 1200-1600kPa
Analysis for low pressure:
49
— Leakage at cylinder head’s gasket
— Incorrect adjustment for valve clearance
— Valve leakage
— Piston ring or cylinder worn out
— Battery power loss, weak starting
Analysis for high pressure:
— Carbon buildup in combustion chamber or on piston’s top.

Cylinder head cover

Disassembly/Re-assembly
Remove the shielding parts such as fuel
tank.
Remove the bolt [1] on cylinder head cover
and oil seal [2].
[1]/[2]

cylinder head and its seal ring [4].

Remove the cylinder head cover [3] from Caution:

50
 Please don’t forcedly remove the
seal ring on cylinder head cover. [4]
 Please check the damage or oil leakage
on seal ring of cylinder head cover. [3]

The re-assembly is precisely opposite to glue.

disassembly.

Torque:
Bolt on cylinder head cover: 10N·m
Caution:
 Replace the seal ring [1] of cylinder
head cover for a new one.
 When re-assembling, align the seal
ring of cylinder head cover to the [1]
semi-circular groove on cylinder head
密封胶
cover and then install in, then
install the cover into cylinder head.
 Coat the contact place of
semi-circular groove and seal ring of
cylinder head cover with sealing
Tensioner
Disassembly/Re-assembly
Remove the seal bolt [1] and seal ring
[2].
Turn the tensioner clockwise by the tool
for it only, make sure the tensioner
completely moved back. [1][2]
[3]
Tool:
Single sheet or screwdriver

51
Remove the installation bolt [3] of
tensioner. [2]
Remove the tensioner [1] and its gasket
[2].

[1]
The re-assembly is precisely opposite to
disassembly.

Fastening torque: 10N·m

Caution:
 Replace the gasket for a new one.
Check
Check the operational performance for
tensioner [1]. [1]
— When pressing down the adjusting rod
of tensioner, the rod shall not be
press into the adjustor.
— When turn the adjusting rod clockwise
by single sheet [2], the rod shall be
pick into tensioner; When the tool
removed, the adjusting rod shall
bounce out from adjustor immediately. [2]

Camshaft
Remove the cylinder head cover.
Make sure the crankshaft and cam is at
timing status (The piston is at upper
stopping point).
Then remove the tensioner.

Remove the bolt [1] on the limit plate of

timing chain, then remove the limit plate
[2] of timing chain.
52
 [2]

[1]

Alternatively loosen the bolts [1] of then remove the camshaft.

camshaft’s bracket by 2 to 3 times, then
remove them.
Remove the bracket [2] of camshaft from
cylinder head.
Caution:
 From outside to inside, alternatively
[2]
loosen the bracket’s bolts, [1]
otherwise the camshaft’s bracket may
[3]
damage.
 Please don’t forcedly remove the
positioning pin from camshaft’s
bracket

Remove the chain [3] from sprocket wheel,

Lift up the swinging arm [1].

Remove the valve adjustment shim [2].
Caution: [2]
 Be careful，don’t let the adjusting
shim of valve drop into engine. [1]
 Mark up the shim to make sure correct
re-assembly.
 Remove shim by tweezers or magnet may
make your work easier.

Check
53
Check the damage, wear-out, distortion, Limit for maintenance: 0.03mm
burn-out or block in oil passage for parts
below:
— Cam’s sprocket wheel/Camshaft
— Camshaft’s bracket/Positioning pin
— Adjusting shim for valve
— Swinging arm
Measure each part according to
specification of cylinder head/valves
Runout of camshaft
Fix the both ends of camshaft by V-shaped
piece, and measure its runout by dial
plate.
Re-assembly:
Make sure the crankshaft is under timing
[1]
status.
Caution:
 When the camshaft bounced out of
tensioner without re-assembling,
when turning the camshaft, make the [2]
chain tense to avoid dropping into
crankshaft. Re-assemble the
adjusting shim [1] back into the
original place on valve’s base ring
in turn.
Lay down the swinging arm [2].

Caution： surface with oil

 “IN” mark [1]:Air inlet camshaft Match and re-assemble the chain and
 “EX”mark [2]:Air exhaust camshaft sprocket wheel of cam, then re-assemble
 When re-assembling, make the chain at the camshaft on cylinder head.
air exhaust side tense and
re-assembly the air exhaust camshaft
first.

Coat the cam, journal and thrusting

surface with oil.
Coat the chain of cam and all their

54
 [1]

[2]

Align the mark [1] IN on sprocket of air

inlet cam with mark [2] EX on sprocket
wheel of air exhaust cam and the upper
surface of cylinder head.

[2] [1]
“EX” “IN”

Make sure the positioning pin of bracket 2-3 times, whose fastening way and torque
of camshaft align with its hole on are show as page 1-15.
cylinder head.
Make sure the left camshaft bracket’s EX
[1] face to the air exhaust side as
picture shows. [1]
Bracket of left camshaft（Mark “L”） [2]
Bracket of right camshaft（Mark “R” ） [3]
Bolt on camshaft’s bracket:
- M6×40mm Bolt [2]
- M6×32mm Bolt [3]
Alternatively fasten the bolts on
camshaft’s bracket to given torque by

Caution:
 The camshaft’s bracket must be  Coat the contact surface of each
replaced with cylinder head as one camshaft’s bracket and seal surface
set. with oil.
55
Re-assemble the pressing plate [1] of
cam’s chain, check its tightness. [2]
Caution: Be careful, don’t let the bolt
of pressing plate on cam’s chain drop
into crankcase.
Re-assemble and fasten the bolt [2] on
pressing plate of cam’s chain.
Fastening torque: 12N·m [1]

Draw off the special on the tail of

tensioner. Turn the crankshaft for
several rounds, then adjust to the status
when it just re-assembled and check the
timing of valve.

Check and adjust the valve clearance

（Refer to page 2-5）. [1]/[2]

Re-assemble the bolt [1] on cylinder head

cover, please also replace the gasket [2]
for a new one.

Re-assemble the cylinder head cover.

Swinging arm
Disassembly/Re-assembly
56
Caution：
 When repairing the swinging arm’s
shaft, we needn’t remove the engine
from frame.
[1][2]
 The steps for repairing swinging
arm’s shaft on air inlet valve and
exhaust valve are the same.
 Remove the camshaft.
Remove the socket screw [1] and copper
washer [2].

Fix the swinging arm [1], and remove its

shaft [3] by the bolt [2] in size of 6mm.
Remove the swinging arm.
Coat the sliding area, force bearing
surface, external surface of swinging
arm’s shaft with lubricant.
Caution:
 The swinging arm could be identified
by its mark:
— “IN” mark [4]: Swinging arm at air
inlet side
— “EX” mark [5]: Swinging arm at air
exhaust side

The re-assembly is precisely opposite to according to specification for cylinder

disassembly. head/valve.
Caution： Any parts passed the limit for
 Coat with oil and replace the copper maintenance, please replace.
washer for a new one.
 Fastening torque for socket hex screw
of swinging arm： [5]
Fastening torque: 13N·m
Check
Check the damage, wear-out, distortion,
burn-out and blocking-up in oil passage
on parts below. [4]
— Swinging arm
— Shaft for swinging arm
Measure each part and their clearance

Cylinder head

57
 Disassembly:
— Disassemble the parts below in turn:
— Muffler
— Air filter and air inlet tube
— Water tube joint of engine
— Electrical connectors
— Other covering parts
Remove the engine from motorcycle and put
it on the bench [1]
Remove cylinder head cover, limit plate
of chain, cam’s bracket, camshaft,
swinging arm, swinging arm shaft and
adjusting shim for valve in turn by
[2]
referring previous chapter.

Remove side bolt [1] of cylinder head.

Remove the noiseless bolt [2].
Loosen the nut [3] of 8mm alternatively [3]
by 2-3 times, then remove the nut and
washer.

Remove the cylinder head.

Caution:
 Please don’t heavily knock the
cylinder head, don’t damage the
contact surface by lever of any tool.

Remove the positioning pin [1] and gasket

[1]
[2].

[2]

58
 Breaking down
Remove the parts below:
— Spark plug [1]
— Water temperature sensor [2]
— Seal ring [3] of cooling joint
Remove the valve locking clip by special
tools.
Tool: [1]
Compressing tool for valve spring
Pressing accessories for valve spring

[2] [3]

Remove the compressing tools of valve chamber and surface of gasket.

spring and parts below：
— Locking clip [1]
— Upper valve spring base [2]
— External spring [3] of valve
— Internal spring [4] of valve
— Valve [5]
— Oil shield cover [6]
— Lower valve spring base ring [7]
Caution:
 Please don’t damage the contact
surface of cylinder and surface of
valve base.
 In order to prevent the permanent
distortion of valve spring, heavy
compression is not allowed.
 Mark up each part when disassembling
for an easy re-assembly.
Clean up the carbon buildup in combustion

— Valve
Check — Guiding tube of valve
Check the damage, wear-out, distortion,
burn-out of blocking up of oil passage on
parts below.
— Cylinder head
— External spring

Re-assembly
59
Wash up the cylinder head set by solvent,
then dry all the oil passage up by blowing
by compressed air
Lubricate the new oil shield cover [1] by
oil.
Re-assemble the spring base [2] of lower
valve and oil shield cover.
Lubricate the sliding surface and rod end
of each valve rod by oil.
Insert the valve [3] into its guiding rod,
slowly turn the valve when inserting.
Re-assemble the internal and external
valve spring [4] [5], the side with denser
coil face to combustion chamber.
Re-assemble spring base ring [6] of upper
valve.
Re-assemble the valve locking clip [7] by
special tools.
Tool:
Compressing tool for valve spring
Compressing accessory for valve spring.

Re-assemble the parts below: — Water temperature sensor [2]

— Spark plug [1] — Cooling joint and seal ring [3]
60
 new gasket [3].

Re-assembly

Clean up the residual gasket of contact

surface of cylinder.
Caution:
[2]
 Don’t let the dust and dirt into
[1]
cylinder.
对 齐
Make the chain tense, re-assemble the
guiding plate [1], then get its [3]
protrusion aligned with groove on
cylinder head.
Re-assemble the positioning pin [2] and

Get the timing chain through cylinder

head, then re-assemble the cylinder head
onto cylinder body.
Coat the threaded part and base surface
of fastening nut (8mm) on cylinder head
with engine oil
Re-assemble the fastening nut and washer
of cylinder head alternatively by 2-3
times to given torque.
Torque: Wet torque 30N.m

Timing chain/Sprocket wheel

61
 Removal
Remove the parts below: [2]
— Cylinder head cover [3]
— Camshaft
— Noiseless bolt of cylinder head
— Left crankcase cover set
— Rotor of magneto
— Plate shaped gear
[4]
Remove the guiding plate [1] for chain,
then remove the pressing plate of [1]
adjusting plate, bolt [2] and tensioning
plate [3] of chain.
Remove the timing chain [4] from
crankshaft.
Check
Check scratch, damage, wear-out and distortion on parts below, please replace the parts
below if it is necessary:
— Timing chain
— Tensioning plate of chain
— Guiding plate of chain

Re-assembly
Coat the all surface of timing chain [1] 扭矩：10N·m
with oil, then match and re-assemble with
[1]
timing driving sprocket wheel. [2]
Re-assemble the tensioning plate [2]of
chain.
Re-assemble guiding plate [3] of chain.
Re-assemble pressing plate of adjusting
[3]
plate and bolt[4]. [5]
Turn the bolt on pressing plate of
adjusting plate to given torque.
Re-assemble the parts below:
— Plate shaped gear
— Rotor of magneto
— Left crankcase cover set
— Noiseless bolt
— Camshaft
— Cylinder head cover

62
 Cylinder head/Piston

Removal
Remove the parts below:
— Cylinder head cover
— Camshaft
— Noiseless bolt of cylinder head
— Left crankcase cover set
— Rotor of magneto
— Plate shaped gear
— Timing chain and tensioning plate

Remove cylinder body [1] ， Remove the

gasket[2] and positioning pin [3] of
cylinder head.

[1]

[3]

[2]

Remove the piston

Remove the circlip [1] of steel wire by tweezers
Push the piston pin [2] out from piston [3] and [2]
smaller end [4] of connecting rod, then remove [1]
the piston.

[3]
[4]

63
Removal for piston ring
Get every opening of piston ring breaking
apart, then remove the ring upwards along
the opposite position of its opening.
Caution：
 Don’t break apart the two ends of
opening too far to avoid damage on
piston ring.
 Please don’t leave scratch on piston when
removing its rings.

Clean up the carbon buildup in groove of

piston ring by replaced ring who is about to
throw away.
Caution:
 Don’t use the steel brush to avoid leaving
scratch on piston ring.

needs be replaced.
Check
Check the scratch, damage, wear-out,
distortion, burn-out or block in oil passage for
parts below.
- Cylinder body
- Piston
- Piston ring
- Piston pin
- Smaller end of connecting rod
Measure every part according to specification
for crankshaft/piston/cylinder/balancing shaft,
then calculate their clearance.
Any part got passed the limit for maintenance
Re-assembly
Totally clean up the groove of piston ring and - Mark“1R” ：1st ring [1]。
install the rings. - Mark“RN” ：2nd ring[2]。
 Coat the surface of piston rings and their  When re-assembling the oil ring set [3],
grooves with oil. install the liner ring [4] first, then the
 Don’t damage the piston and its rings scratching ring [5].
when re-assembling.  Get the opening on piston rings mutually
 安 The side of piston ring with mark face cross by 120°.
upwards when re-assembling. The staggering position for openings on

64
 scratching ring is shown as picture.

Coat the internal surface of piston pin’s hole  Don’t align the opening of steel wire
with oil. circlip with the gap on piston.
Coat the internal surface of smaller end of
[1]
connecting rod with oil.
Re-assemble steel wire circlip [1] onto one end
of piston pin’s hole. [2]
There is mark IN at piston [2] as picture shows,
it faces to air inlet side, coat the external
surface of piston pin with oil, get piston pin [3]
through piston and connecting rod, then IN [3]
assemble steel wire circlip on the other side.
Caution:
 Make sure the steel wire circlip was
assembled in place.

Coat the case combination plate with sealing

glue [1], then re-assemble the gasket [2] and
positioning pin [3] of cylinder body.

[2][3]
[1]

65
Coat the cylinder wall and thrusting surface
with oil. [1]
Re-assemble the piston/connecting rod set [1]
into cylinder body [2] (The side on piston with
mark IN face to air inlet direction) by
compressing tools for piston ring which could
be found from market.

[2]

Caution:
 When re-assembling the piston, please don’t damage the upper surface of piston, especially
the matching part with cylinder hole.
 Please don’t damage the cylinder liner by crankshaft pin and connecting rod.
 Make sure the piston repeatedly move up and down in cylinder body freely without noise and
jamming.

Stud/Pressing pin piece

Disassembly
Fasten the stud by its tool [1], then
remove the stud [2].
[1]

[2]

66
Fasten the pressing pin piece by the bolt
[3] of M3 for it only, then remove the
elastic circlip [2] and pressing pin [1]
piece set [3]. [3]

[2]

Remove the bolt [1] of M3 from pressing

pin piece set, then remove flat washer [2], [2] [3]
pressing spring and pressing pin piece
[4].
Caution:
 Check the damage, wear-out, or distortion
on pressing pin piece, in case it is, please [1] [4]
replace the corresponding parts.

Re-assembly
Re-assembly is opposite step for
disassembly, put the pressing spring and [2]
flat washer into pressing pin piece in
turn, then fasten them by bolt M3 for them
only, then let the upper end of flat
washer is lower than the lower rim of
circlip’s groove.
Put the well assembled pressing pin piece [1]
set [1] into the hole [2] on crankcase,
the inclined surface of pressing pin
piece face to the angle R of external ring
of crankshaft’s bearing.

67
Assemble the elastic circlip [1] to its
groove by caliper, then turn the circlip
and confirm it is in place, then remove [2]
the bolt M3 [2], finally confirm the
pressing pin piece is normal.

[1]

Turn the longer threaded part of stud [2]

into left crankcase body by tool [1] and
fasten.
Fastening torque: (3～5)N.m
Exposing length after fastened (127～
129.5)mm。
[2] [1]

6
Clutch and gearshift system
Information for maintenance…………………………………….…68
Specification for clutch and gearshift system…………….…68
Troubleshooting…………………………………………………….…69
Layout for components…………………………………….…………70
Right crankcase cover………………………………….……………71

68
Clutch……………………………………………………………..……73
Primary driving gear…………………………………………………78
Gearshift system………………………………………………………80

Information for maintenance

Summary
 The maintenance for clutch and gearshift device in this chapter needn’t remove
the engine from frame.
 The oil level and viscosity has influence on separation of clutch. When the clutch
failed to separate or the motorcycle is still in low speed when clutch separated,
please check the oil level before clutch maintenance.

Tool

Specification for clutch and gearshift device

69
 Unit：mm
Items Standard Limit

Free travel for clutch lever 10．0-20.0 —

Clutch Free length for 28.2-28.8 27.10

spring
Thickness of 2.35-3.45 2.20
friction plate
Flatness for driven — 0.10
plate
Collar of clutch Internal diameter 17.000-17.018 17.031

External diameter 23.972-23.93 23.96

External diameter for main shaft at 16.966-16.984 16.95

clutch’s collar

Troubleshooting
Difficult to hold clutch lever tightly
 The clutch cable damaged, twisted or too dirty
 Wrong wiring for clutch cable
 The thrust mechanism of clutch got damaged
 Malfunction in bearing of clutch’s pushing rod
 Incorrect installation for operational rod of clutch

Clutch skidding in acceleration

 Jamming on clutch’s pushing rod
 Driving friction plate worn out
 Poor performance for clutch spring
 Not any free travel on clutch lever
 Molybdenum disulfide or graphite additive gets into oil

When clutch separated or failed to separate, the motorcycle is still under low speed
 Too wide the free travel of clutch lever
 The friction plate of clutch gets warped
 Too high the oil level, wrong viscosity or incorrect additive
 The locking nut on clutch center case gets loosened
 Thrust mechanism of clutch gets damaged
 Incorrect installation for clutch’s operational rod
 The inserting groove on clutch outer case and clutch gear worn out
 Wrong operation for clutch
70
Difficult gearshift
 Incorrect adjustment for clutch cable
 Wrong operation on clutch
 Wrong viscosity of oil
 The gearshift fork gets damaged or bent
 The shaft of gearshift fork gets bent
 The claw of gearshift fork gets bent
 The bolt on five-star shaped plate gets loosened
 The five-star shaped turning plate gets damaged
 The guiding groove on gearshift drum gets damaged
 Five-star shaped turning plate gets worn out or damaged

Gear jump in transmission system

 Check plate gets worn out
 Poor performance even damage on returning spring of check plate
 The bolt on five-star shaped turning plate gets loosened
 Five-star shaped turning plate gets damaged
 Shaft of gearshift fork gets bent, gearshift fork gets bent or damaged
 The meshing surface or teeth groove gets damaged

Gearshift plate fail to return

 The poor elasticity of returning spring of gearshift spindle or gets cracked
 Gearshift spindle gets bent or damaged

Layout for components

71
 Right crankcase cover

Disassembly
Remove the shielding parts of motorcycle. for clutch drawing cable, then remove the
Drain off the oil in engine and the clutch cable [4] from clutch operational
coolant. arm [3].
Remove the bolt [1] and locating plate [2]
72
 [3] [4]

[2]

[1]

Loosen the tube clip [1] of water inlet [2]

tube, then remove the water inlet tube [2]
from cooling pump cover [3]. [4]
Loosen the bolt [4] of right crankcase [1]
cover in alternative sequence by 2-3
times. [3]
Remove the parts below:
— Bolt [4]
— Right crankcase cover [5]
[5]

Remove positioning pin [1], collar’s

seal ring set [2] and gasket [3].
[3]

[1]

[2]

73
Disassembly/Re-assembly

Remove the ejector rod [1], remove the

[4]
turning spring [2].
Caution:
 Insert the inclined end of turning [2]
spring for installation into
operational rod, another end put into [1]
clipping groove on right side cover.

Remove the operational rod [3] of clutch. [3]

Remove the damping sheet and its cover
[4].
Remove the oil seal from right crankcase
cover.
Re-assembly is precisely opposite to
disassembly.

Disassembly and re-assembly for cooling pump set please refer to the page 3-9.
Torque:
Bolt on right crankcase cover: 10N·m
suggested, then check the oil
Caution: leakage.
 Replace the gasket for right
crankcase cover for a new one.
 The 2 bolts for positioning pin on
right crankcase cover are longer than
others, please pay attention to their
assembling position.
 Adjust the free travel of clutch
lever.
 Fill up the crankcase with oil of our

74
 Clutch

Disassembly
Remove the right crankcase cover.
Remove the bolt [1] for oil pump and the
pump [2] itself.
[1]
Remove the bearing [3] for pressing plate
of clutch. [2]

[3]

Stop the joint of clutch gear and primary

[1]
driving gear by special tool [1],then
remove the locking nut [2] and washer [3]
by torque wrench.

Tool:
[1] Gear stopper

[2][3]

Remove the central case set [1] of clutch.

[1]

75
Remove the bolt [1] on lifting plate of meanwhile fastening the locking nut.
clutch alternatively by 2-3 times, then
remove the lifting plate [2] and clutch
spring [3].
[1]

Caution:
[3]
 Under this condition, the driving and
[2]
driven friction plate could be
replaced separately.
 Don’t damage the surroundings of
clutch and keep it clean.。
Fix the lifting plate of clutch by tools,

Remove the parts below:

— Pressing plate [1]
— Driving friction plate [2] of clutch
— Driven friction plate [3] of clutch
— Central case [4]

[1] [2] [3] [4]

Remove thrust washer [1].

Remove outer case [2] of clutch.

[1]

[2]

Remove collar [1] of clutch and its washer

[2].
[2]

[1]

76
Check
Check the scratch, damage, wear-out or distortion on parts below, in case it is, please
replace.
— Pressing plate of clutch
— Bearing for clutch pressing plate
— Spring
— Central case
— Flat washer
— Disc spring
— Driving and driven friction plate
— Outer case of clutch/Primary driven gear
— Collar of clutch
Measure each part according to specification for clutch and gearshift device.
In case any part passed the limit, please replace.
Caution:
 Replace the springs on clutch as a complete set.
 Replace the driving and driven plate of clutch as a pair or complete set.

Re-assembly

77
Coat the external surface of clutch
collar with oil, then re-assemble the
flat washer [1] and clutch collar [2] onto
main shaft.

[1]
[2]

When re-assembling the outer case, turn

the primary driving gear [1] and make sure
its correct meshing.
Caution:
 Confirm the outer case was [1]
re-assembled in place, make sure the
correct meshing between plate shaped
gear on clutch outer case and primary
driving gear.

齐平

Re-assemble the thrust washer [1].

[1]

78
Fix the central case [1], from the driving
friction plate [2], re-assemble the
driving and driven friction plate [3] to
the central case alternatively, finally
well cover the pressing plate [4].

Caution: [1] [2] [3] [4]

 Get the teeth on driving friction
plate align with that on outer case
one by one.

Re-assemble clutch spring [1], pressing

plate [2] and fasten bolt [3].
Slowly and alternatively fasten the bolt
on lifting plate by several times and
fasten to given torque. [1] [1]
Torque: 12N·m
[2]

Re-assemble the central case set [1] of

clutch, then assemble the locking nut and
washer [2] onto main shaft, then stop the
joint between clutch gear and primary
[1]
driving gear by tool, finally fasten the
[2]
locking nut of clutch to given torque by
torque wrench.
Tool:
Gear stopper
Torque: 74N·m

Re-assemble oil pump and right crankcase cover.

79
 Primary driving gear

Disassembly
Remove right crankcase cover and oil pump.
Fix the primary driving gear and outer
case of clutch by special tool [5], then [3]
remove bolt [1] on primary driving gear
and washer [2].
Remove clutch set [3].
Remove primary driving gear and flat [5]
washer [4]. [4]
Special tool:
[5] Gear stopper
[1]/[2]
Check
Check the scratch, damage, wear-out and distortion on parts below, replace if it is
necessary.
— Primary driving gear
— Bolt
— Washer

Re-assembly
Align the flat washer [1] with the
semi-round key [2] on right crankshaft,
then assemble into right crankshaft.
Align the key groove on primary driving [3]
gear [3] with the semi-round key on right
crankshaft, then assemble into right
crankshaft.

[2]

[1]

80
Then assemble the flat washer [1] and hex.
Flange nut [2] in turn and turn in by 2-3
thread by hand.

[2] [1]

Re-assemble the outer case of clutch, fix

the primary driving gear and outer case
of clutch by special tool [1], then fasten
the bolt [2] of the gear.
Caution:
 Re-assemble the primary driving gear
first, then the outer case of clutch.
 The outer case of clutch as clearance
[2]
for axial runout.

Tool [1]:
Gear stopper [2]
Torque: 74N·m

Re-assemble clutch, oil pump and right crankcase cover.

81
 Gearshift system

Disassembly
Drain off oil and remove the parts below:
[2]
— Remove the gearshift pedal and clean [1]
up the dirt on spline
— Right crankcase cover set
— Clutch set
Remove the bolt [1] of check plate first,
[3] [4]
then the check plate [2], returning
spring [3] and washer [4].

Remove the parts below

— Bolt [1] of five star shaped plate
— Five-star shaped plate [2]
— Positioning pin [3] [2]/[3] [1]

Draw the gearshift spindle set [1] and

thrust washer [2] out of crankcase.
Remove oil seal [3] from left crankcase
body. [2]

[1]
[3]

82
Check
Check damage, wear-out or distortion on parts below, in case it is, please replace.
— Five-star plate
— Check plate
— Return spring for check plate

Gearshift arm
Check the wear-out or fatigue on twist [3]
spring [1] on gearshift arm and drawing
spring [2] on gearshift plate；Check the
wear-out or bending on gearshift spindle;
Check wear-out, damage or distortion on
[2]
gearshift plate [4].
In case it is necessary to replace, please
replace the gearshift arm set completely. [1]
[4

Re-assembly
Re-assemble the thrust washer [1] and
gearshift arm [2] into crankcase, then [1]
clip the gearshift turning spring into [2]
locating bolt of gearshift arm.
卡入

Re-assemble the positioning pin [1] into

its hole on gearshift drum. Re-assemble
five star shaped plate [2], then get its
pin’s nail align with positioning pin
downwards, then assemble into gearshift [1]/[2] [3]
drum. Re-assemble the locating bolt [3]
of five star shaped plate, coat the head
of bolt with Loctite and fasten to given
torque.
Torque: 12N·m

83
Re-assemble the thrust washer [1],
[3]
returning spring [2] and check plate [3] [4]
onto its bolt [4], coat the threaded part
of bolt with Loctite, assemble to
crankcase body and fasten to given
torque.
Torque: 12N·m [2] [1]

Caution:
- When re-assembling, the protrusion on
five-star plate face to crankcase, the
roller of check plate face to crankcase
- The U shaped hook of returning spring
face upwards and stick to semi-round
key’s groove of check plate.
- Turn the bolt of turning plate on
gearshift drum by T-shaped plate, then
check the gearshift of each gear position
in turn of clockwise and anti-clockwise.

Coat the external surface of gearshift spindle with clean engine oil.
Re-assemble the oil seal [1] of gearshift spindle to left crankcase body.
Caution:
 Re-assemble the oil seal to given [1]
depth as picture shows.

Re-assemble clutch set and right

crankcase cover set, then check the
oil level.

84
 7
Magneto and starting clutch
Information for maintenance………………………….………84
Specification for magneto and starting clutch…….……84
Troubleshooting……………………………………….…………84
Position for components………………………………….……85
Left crankcase cover……………………………………………86
Stator of magneto and trigger………………….……………87
Rotor of magneto…………………………………………………88
Starting clutch…………………………….……………………90

85
 Information for maintenance
Summary
 The maintenance for stator and rotor of magneto needn’t remove the engine from frame.
 Check about the charging coil of alternative power generator.
 Check about the trigger.
 Maintenance about starting motor.

Specification for magneto and starting clutch

 Unit：mm
Items Standard Limit
External diameter for 42.195-42.208 42.175
shaft jacket of starting
plate shaped gear
Internal diameter for 28.02-28.041 28.061
outer case of starting
clutch

Tool(s)
Fixture for rotor Removal tool for magneto

Troubleshooting
Starting motor is run, while engine failed starting
 Malfunction in starting clutch
 Malfunction in double gear or its shaft of starting motor
 Smaller gear of starting motor in malfunction or worn out

86
 Position for components

Left crankcase cover

Disassembly/Re-assembly
Caution: — Connector of trigger
 When disassembling the left crankcase
cover, lay a clean oil tray under it
to prevent oil flowing out. When
re-assembled, fill up our suggested
oil to given volume.
Lay the motorcycle on horizontal ground
and make it upright.
Remove the parts below:
— Shielding parts
— Connector of rectifier regulator

Loosen the bolts [1] on left crankcase

cover in alternative way and the wire
pressing plate.
Caution:
 The left crankcase cover (Stator) is
under the magnetic attraction of
rotor, please pay attention to safety
when disassembling or re-assembling.

87
 [1]

Remove the positioning pin [1] and gasket [1]

[2].
The re-assembly is precisely opposite to [2]
disassembly.
Torque:
Bolt on left crankcase cover: 10N·m

Caution:
 Replace the gasket of left crankcase cover for a new one, then check the oil level.

 Make sure there is not any oil leakage.

Stator of magneto and trigger

Disassembly/Re-assembly
Remove the left crankcase.
Disassemble and re-assemble the stator/trigger as picture below shows:
 Coat the threaded part of bolt on stator and trigger with Loctite.
 Coat the sealing surface of wire’s ring jacket of magneto/trigger with sealing
glue.
The re-assembly is precisely opposite to disassembly.

88
六角头法兰面螺栓：Hex. Flange bolt 触发器：Trigger 锭子：Stator
左前盖：Left front cover

Rotor of magneto
Disassembly
Remove the left crankcase cover.
Remove limit collar [1], double gear [3] [1] [3]
and its shaft [2]. [2]

89
Fix the rotor [1] of magneto by its fixer,
[1]
then loosen bolt [2] and washer [3], then
move bolt outwards by 5-10mm without
completely removed for a easy disassembly
for rotor latter.
[2][3]

Remove the rotor [1] of magneto by special

tool [2].
Tool:
[1] [2]
[2] Removing tool for rotor

Caution
 To avoid damage on threaded part with
conical degree on crankshaft, the
tool can’t push up the crankshaft
directly, the tool needs to push up
the head of bolt.

Remove the bolt of rotor.

Check
Check the scratch, damage, wear-out or distortion on parts below. Please replace if
it is necessary.
— Shaft of double gear
— Double gear

Re-assembly
Check the damage on semi-round key [1].
Coat the gear plate part of left
crankshaft with oil, then totally clean
up the oil and impurities in conical
surface of crankshaft and internal hole [1]
of rotor.

90
Re-assemble rotor [1], align the [1]
semi-round key on crankshaft with key’s
groove on rotor.

对齐

Coat the threaded part of rotor’s bolt

and installation surface with clean
[3]
engine oil.
Re-assemble shim [1] and bolt [2] of
rotor.
Fix the rotor [3] by its fixer and fasten [1][2]
the bolt to given torque.
Torque: 64N·m

Re-assemble the double gear [1], its

shaft [2] and limit collar [3].
[1]
Re-assemble the left crankcase cover.

[2] [3]

Starting clutch
Check the operation of starting clutch
Remove the rotor. Check and confirm the anti-clockwise
Check the operational performance of turning of plate shaped gear is smooth and
starting clutch by turning plate shaped without clockwise turning.
gear [1].
91
 [1]

Disassembly
Remove the rotor. [1]
Turn the plate shaped gear anti-clockwise
and remove it [1].

Fix the rotor [1] by its fixer, then

remove the fastening bolt [2] of starting [1]
clutch.

[2]

Remove the starting clutch set.

Remove the starting clutch body set [2]
from rotor [1].
92
 [1] [2]

Check
Check the scratch, damage, wear-out or distortion on parts below. Please replace if
it is necessary.
— Plate shaped gear
— Holding bracket for starting clutch
— Roller for starting clutch
Make sure each part meets the specification for magneto and starting clutch.
In case any part passed the limit for maintenance, please replace.
Re-assembly

盘齿：Plate shaped gear

单向器外圈：Outer ring for one-way device
[2]
[1]
单向器：One-way device 转子：Rotor
Coat the contact surface of starting
clutch with clean engine oil.
Re-assemble the starting clutch body set
[1] onto rotor [2].

93
Fix the rotor [1] by its fixer. [1]
[2]
Caution:
 Coat Loctite to threaded part of bolt
on clutch
Re-assemble and fasten the fastening bolt
[3] to given torque.
Torque: 29N·m [3]

Turn the plate shaped gear [1]

anti-clockwise, then re-assemble the
gear into outer case of starting clutch.
Check the operational performance for
starting clutch.

Re-assemble the rotor.

Crankcase body and transmission system

Information for maintenance…………………………………………94
Specification for case body and transmission system…………95
Troubleshooting………………………………………..………………95
94
Layout for components…………………………………………………96
Crankcase body………………………………….………………………97
Gearshift system……………………………………….…………………100
Transmission system………………………………………………………101

Information for maintenance

Summary
 Break up the crankcase for the maintenance and replacement below:
1. Transmission system
2. Crankshaft and connecting rod system
 Remove the parts below before breaking up the crankcase:
1. Cylinder head set
2. Cylinder body set
3. Air system and related parts
4. Pressing pin piece
95
 5. Right crankcase cover set
6. Oil pump set
7. Clutch set
8. Primary driving gear
9. Gearshift system set
10. Starting motor set
11. Left front cover set
12. Double gear set
13. Magneto set
 Please don’t damage the combination surface of crankcase when repairing.
 Wash up the oil passage and combination surface before re-assembling the crankcase.
 Before combining the case, coat the combination surface with sealing glue for end surface
evenly, the surplus sealing glue must be cleaned up.

Specification for crankcase body and transmission system

Unit: mm

Items Standard Limit

Diameter of M5、M6 20.00-20.021 20.07
gear’s C3、C4 22.02-22.033 22.08
internal hole C2 23.02-23.041 23.09
C1 18.02-18.033 18.08
External C1 17.979-18.00 17.90
diameter of
Transmission shaft’s
system jacket
Internal C1 15.00-15.021 15.10
diameter of
shaft’s
jacket
Diameter for Matching with 16.959-16.98 16.93
main shaft shaft’ jacket
of M5
Diameter for Gear matching with 19.978-19.989 19.92
countershaft shaft’s jacket of
C2
Matching with 14.966-14.984 14.90
shaft’s jacket of
C1
Clearance Gear matching with 0.02-0.054 0.10
between main shaft’ jacket
and counter of M5

96
 shaft
Clearance C2 0.02-0.054 0.10
between C1 0.02-0.054 0.10
shaft’s
jacket and gear
Clearance C2 0.02-0.062 0.10
between C1 0.016-0.055 0.10
shaft’s
jacket and main
or counter
shaft
Gearshift Diameter for gearshift fork’s shaft 9.966-9.984 9.91
fork and its Internal diameter of gearshift fork 10.00 -10.018 10.03
shaft Thickness of gearshift fork’s tip 4.93-5.00 4.90

Troubleshooting
Noisy engine
 Transmission gear worn out or damaged
 Transmission bearing worn out or damaged

Layout for components

Crankcase body
— Primary driving gear
Disassembly/Re-assembly — Gearshift system set
Remove the parts below Loosen case combination bolt M6× 65[1]
— Left cover set and M6×35[2] by 2 times.
— Right crankcase cover set
— Starting motor set
— Magneto set
— Pressing pin piece
— Clutch set
— Oil pump set

97
 [2] [1]

Put the engine up side down.

Loosen bolt M6×65[1] on left crankcase
body and M6×40[2] by 2 times, then remove
all the bolts.
[1]

[2]

Remove the left crankcase body [1] from the

right one [2] (Caution: Please don’t pry up the [1]
case combination surface of crankcase by tools,
knock the surface without machining by rubber
hammer can easily remove it).

[2]

Remove positioning pin [1]. Remove gearshift

drum [2], gearshift fork and its shaft [3], then
remove main and counter shaft set [4] (Whose
disassembly and re-assembly refer to chapter
later), remove crankshaft [5] and balancing
shaft [6] (Whose disassembly and re-assembly
refer to chapter 9th).

98
 [2]

[4] [5]
[6]
[3]

[1]
Re-assembly
Wash up the combination surface of left and
right crankcase and don’t damage the surface.
Check the blocking-up in the oil passage of
crankcase, wash it up when it is necessary.

Case combination
Re-assemble the main & counter shaft set,
crankshaft & balancing shaft to right
crankcase (Whose details refer to later
chapter and chapter 9th).
Re-assemble the gearshift drum set, fork, and
fork shaft to right crankcase (Refer to chapter
later)
Evenly coat the combination surface of left
crankcase with sealing glue as picture at right
side shows.
Caution:
 Too much the end surface sealing glue is
not allowed.
 Don’t spread the end surface sealing glue
to bolt of main shaft’s journal and hole of
oil passage.

[2]
Re-assemble the positioning pin [1] onto
crankcase body [2].

[1]

99
Check the gears between main and counter
shaft are aligned and make them at neutral gear.
Check once again and confirm all the parts on
crankcase body are assembled in place.
对齐

Re-assemble the left crankcase body [1] onto

the right one [2].
Caution:
 The case combination bolt already used
can’t be adopted once again.
 Confirm the clearance between crankshaft
and crankcase body is within (0.05-0.418).
[2]
 Confirm the flexible turning of crankshaft
without noise and jamming.

[2]

Confirm the left and right crankcase are firmly assembled.

Replace the flat washer and case combination bolt for new ones, then fasten the bolt to given
torque.
Torque: The torque and fastening please refer to page 1-13.

Gearshift system

Disassembly
Break up the crankcase body.
Remove gearshift fork’s shaft [1], then
the gearshift drum [3], finally the fork
itself [2].
Check the damage and defects on gearshift fork,
its shaft and gearshift drum.
100
 [2]

[1]

[3]

Re-assembly:
The gearshift fork is with mark as below:
“L”：Left fork
“C”：Middle fork
“R”：Right fork
Coat the guiding area and pin of gearshift fork
with oil.

Press down the right fork [2], middle one

[3] and the left one [4] in turn from main
and counter shaft [1] into gear groove
on the shafts, the side with mark face [4] [3]
upwards (Face to the left crankcase
body). [1]

[2]

crankcase body, then assemble the

Coat the journal with threaded hole on fork’s pin into its groove, coat the
gearshift drum [1] and groove of fork’s shaft [2] with oil, then get
gearshift forks with oil, then assemble through the hole on three forks and
downwards to bearing’s hole on right re-assemble into crankcase body.
101
Caution:
 When re-assembling the fork into its
guiding groove on gearshift drum, [1]
lift up the fork and clip it into
neutral gear, so when the fork’s
[2]
shaft assembled in place, the main
and counter shaft could be freely
turned.

Transmission system

Disassembly
Remove the counter shaft [1].
Remove the main shaft [2].

[1]
[2]

Bread up the main shaft set [1] and

countershaft set [2].
Caution: [1]
 Put the removed gears, collars, washers,
and circlip rings in a line in a special
container.。
 Don’t expand the circlip ring passed its
limit, when removing it, expand it first, [2]
then push it out by the gear behind it.。
 The gears on main shaft adopt
interference fit, which could not be
removed or replaced, in case there is
damage, please replace the main shaft as
a complete set.

102
 Check
Check the scratch, damage, wear-out and distortion for parts below, replace if it is necessary.
 Transmission gear
 Transmission shaft’s jacket
 Gearshift drum
 Gearshift fork
 Gearshift fork’s shaft
Measure size for every part and calculate their matching clearance according to standard.
In case any part’s matching clearance passed the standard limit, please replace it for a new one.

Re-assembly for main and counter shaft

Wash and clean all the parts by solvent and make them totally dry up.
Coat the surface of teeth, turning area and bearing of gears with oil. Coat the outer surface of
gear’s spline jacket, collar, turning area of needle bearing and groove of gear changer with oil.
Re-assemble the main shaft and counter shaft.
Caution：
 Coat every gear with oil and check its smooth and stable turning.
 Get the inner spline of spline washer aligned with its groove.
 Re-assemble the thrust washer always along the axial thrust surface of gear.

 When re-assembling the circlip ring, get its opening gap aligned with spline groove [1].
 Make sure the circlip is completely in the shaft’s groove when re-assembled.

Re-assembly
Coat the journal on the right end of main shaft
[1] and counter shaft [2] with oil, then mesh up 对齐
the corresponding gears on main and counter
shaft, then assemble the main and counter
shaft set into bearing’s hole [3] on the right 1
crankcase.
2

Caution:
 The main and counter shaft shall be freely
turned without jamming.
 The washer on the left end of main shaft, 3
and the washer on the both ends of
countershaft shall be without dropping.

9
Crankshaft, balancing shaft and accessories for
103
 case body
Information for maintenance………………………………………104
Specification for crankshaft/Balancing shaft…………….…104
Troubleshooting………………………………………………………104
Layout for components………………………………………………105
Crankshaft/Balancing shaft…………………………………….…106
Accessories for left and right crankcase body………………108

104
 Information for maintenance
Summary
When maintaining the crankshaft and balancing shaft, the crankcase must break up. How to break
up please refer to previous chapter.

Specification for crankshaft and balancing shaft

Unit：mm
Items Standard Limit
Crankshaft Clearance between crankshaft 0.10-0.35 0.38
and connecting rod
Radial clearance of bigger end 0.005-0.015 0.025
of connecting rod
Runout 0.03 0.05
Internal diameter for smaller end of connecting rod 14.013-14.025 14.045
Matching clearance between connecting rod and its 0.013-0.030 0.05
pin

Troubleshooting
Engine shaking
 Too strong the crankshaft runout

Noisy engine
 Gear on balancing shaft gets damaged

105
Layout for components

106
 Crankshaft and balancing shaft
Disassembly
Before removing crankshaft and balancing
shaft, please remove the parts below:
— Right crankcase body
— Gearshift drum and fork
— Main and counter shaft
Caution:
 The maintenance for parts above please
refer to the chapter 8th for gearshift and
transmission system.
[2]
Fix the left crankcase body [1], remove the
[3]
crankshaft [2] and balancing shaft [3] together
from left crankcase body.

[1]
Check
Hold the journal on both ends of crankshaft.
Lay a micrometer at the middle above journal
of main shaft, please avoid the oil groove and
hole.
Turn the crankshaft by 2 rounds（720°）, then
read its runout.。
Limit for maintenance: 0.05 mm

Check the driven gear of balancing gear, check

scratch, damage, wear-out or distortion on
parts below, in case it is, please replace.
- Driven gear of balancing shaft and pressing
spring
- Balancing shaft

Breaking up
Remove elastic circlip of balancing shaft, then remove the shoulder circlip, disc washer,
107
shoulder circlip, damping rubber, pressing
spring and driven gear of balancing shaft in
turn.
Caution:
Check damage, wear-out or distortion on parts
below, in case it is, please replace.
— Driven gear of balancing shaft
— Pressing spring
— Balancing shaft

Re-assembly internal ring groove of balancing shaft

Coat the internal hole of driven gear of without permanent distortion.
balancing shaft with oil, then re-assemble
driven gear [1], pressing spring [2], damping [3]
rubber [3], flat washer (With external [1]
diameter of 45mm)[4], disc washer [5], [4]
shoulder circlip (With external diameter of [6]
36mm)[6], and elastic circlip onto balancing [2]
shaft.
Caution: [7]
 The side with mark on driven gear face
outwards.
 The driven gear and internal semi-round
groove made up a complete circle without [5]
mislocate.
 The elastic circlip completely clipped into

Put the right crankcase [1] on the bench with jamming or mislocate.
case combination surface face upwards, coat
the journal at right end of balancing shaft [2] [2]
and crankshaft [3] with oil, align the driving
gear of balancing shaft with mark point [4] on
crankshaft, then mesh up the driving and
driven gear, finally assemble the crankshaft and
balancing shaft into bearing hole on right
crankcase body. [3]
Caution:
Align the points on crankshaft and balancing [1]
shaft first, then assemble into right crankcase
bearing’s hole, otherwise it may lead to

108
 Check
The crankshaft and balancing shaft must turn
freely without jamming, turn the crankshaft
and balancing shaft for a round and check the
balancing gear’s aligning point [4], who keeps a
correct position.
[4]

Accessories for left and right crankcase body

Removal
Before maintaining left and right crankcase, we
need to remove the parts below:
— Gearshift drum, fork
— Main and counter shaft
— Crankshaft
— Balancing shaft

Remove the screw plug [1] for sealing and flat

washer [2]. [2]

[1]

109
Remove the fastening bolt [1] for gear
indicating switch set on left crankcase body,
then remove the switch set [2].
[2]

[1]

Remove the check plate for bearing on main [1]

shaft on right crankcase body and the bolt [1].

Heat the left and right crankcase by oven for 30

min, then take out, remove the bearing [1] for
crankshaft on left and right crankcase body,
then the balancing shaft bearing [2], main shaft
bearing [3], counter shaft bearing [4] and [4]
bearing [5] on gearshift drum. [2] [3
[5]

[1]

Caution:
 The oven is hot when it is working, please
wear gloves for protection and adopt
specialized tools before operation.

110
 [2]

[4

[3]

Check
Check jamming, damage, wear-out or
distortion on each bearing, in case it is, please
replace

Re-assembly
Coat suitable lubricant in bearing’s hole, whose
side with letter face upwards(In case it is a seal
bearing of single side, the sealing side face [4]
[2] [3
downwards), then press-fit bearings below into [5]
case body by tools for them only, and check
bearing’s depth：
— Crankshaft bearing [1]
— Balancing shaft bearing [2]
— Main shaft bearing [3]
— Counter shaft bearing [4] [1]
— Gearshift drum bearing [5]

[2]
Caution:
 The tool could be the machine for [4
press-fitting or other specialized tools, but
don’t knock the internal ring of bearings.

[3]

111
Re-assemble the check plate [1] for bearing of
main shaft on right crankcase, coat the head of
bolt [2] with Loctite then assemble into its hole. [2]
Assembling torque:
10N.m

[1]

Re-assemble pressing pin and moving contact

[1], coat seal ring of gear indicator with suitable
grease and re-assemble gear indicator [2], [2]
when press-fitted the gear indicator in place,
fasten by bolt [3].

[3]

Re-assemble the screw plug [1] for sealing and

flat washer [2] on left crankcase body. [2]

[1]

112