AU200 Maintenance Manual

KAYO MOTO
AU200
Maintenance Manual
1
W W W . K A Y O MOTO.COM
Version code：20180915
Version name：AU200 Maintenance manual English version.pdf
WWW.KAYOMOTO.COM
2
Kayo Moto
2018- 08
actual state of the vehicle.
Description
This manual specificially descripted
the maintenance adjustment procedures Kayo Moto
for the AU200 four-wheels vehicle (ATV), Research and Development Department
disassembly and assembly methods, 2018 - 08
inspection and maintenance points,
troubleshooting methods and
maintenance technical data, and detail
graphic data.
Please read this manual carefully and
follow the standard operating methods to
effectively extend the service life of each
component, improve engine performance
and vehicle reliability.
The first chapter mainly introduces
general work items, tools used, basic Contents
technology and maintenance parameters.
Maintenance information 1
The second chapter introduces the
assembly and disassembly operation of Body Plastic 2
the whole vehicle plastic parts.
The third chapter introduces the Regular inspection and
3
regular inspection and adjustment of the adjustment
whole vehicle. Engine periphery 4
The fourth chapter introduces the
disassembly of the engine peripheral Engine 5
assembly parts.
The fifth chapter introduces the Vehicle chassis 6
methods and notice for disassembly,
inspection, maintenance and assembly of Signal and lighting system 7
various parts of the engine.
Electrical schematic appendix
Chapter 6 introduces vehicle chassis
related information
Chapter 7 introduces the inspection
and maintenance information of the
vehicle signal and lighting system.
Appendix: Electrical Schematic
The contents of this manual are subject

to change without further notice due to
improvements in the vehicle.
Maintenance should be based on the
3
4
浙江华洋赛车股份有限公司
Unit conversion table
Item Unit conversion

1kgf/cm2=98.0665kPa；1kPa=1000Pa
Pressure
1mmHg=133.322Pa=0.133322kPa
Torque 1kgf·m=9.80665N·m
1mL=1cm3=1cc
Volume
1L=1000cm3
Force 1kgf=9.80665N
Length 1in=25.4mm
Warning
Please read the following explanation carefully, which emphasizes the

specific meaning of the words “danger”, “warning” and “attention”, and pay
special attention to the outstanding meaning of the engine when repairing it.
Danger: Be alert to high risk

Warning: Indicates caution against moderate risks
Note: Indicates concern for mild danger
However, please note that the “Danger” and “Warning” contained in this
Manual are unlikely to cover all potential risk during engine use and maintenance.
Therefore, in addition to the relevant provisions of “danger” and “warning”,
maintenance operator must also have basic mechanical safety knowledge. If you
are not sure of completing the entire maintenance operation, please consult a
more experienced senior technician.
5
1 Maintenance information
1.1Notes for Operation……………………………………………………………………………1-1
1.2 Vehicle identification number…………………………………………………………………1-3
1.3 Main parameter list……………………………………………………………………………1-4
1.4 Maintenance parameter list……………………………………………………………………1-6
1.5 Tightening torque………………………………………………………………………………1-8
1.6 Lubricant, sealant………………………………………………………………………………1-10
1.7 Cable, hose, cable wiring diagram……………………………………………………………1-11
1.1 Work precautions
Safety Precautions
1. Work clothes (such as overalls), hats, and safety boots that are suitable for the work must be worn.
If necessary, wear protective glasses such as dust-proof glasses, dust masks, gloves, etc. to protect
your body.
2. Since the exhaust gas contains harmful components, it is forbidden to operate the engine for a long
time in a closed place and a place with poor ventilation.
3. When the engine is stopped, the temperature of the engine and muffler is still very high. Do not
touch before cooling to avoid burns.
4, Battery solution (dilute sulfuric acid) is a strong corrosive agent, there will be burns, blindness
when exposed to the skin, eyes. If the clothes and skin are inadvertently stained with the battery
solution, rinse immediately with plenty of water and go to the hospital for treatment. The battery and
battery solution should be kept strictly and must be kept in a safe place that children can't get. When
the battery is charged, it will produce flammable and explosive hydrogen. If there is a fire source or
an electric spark is approaching, there is a danger of explosion. Please charge in a well ventilated
area.
5. Since gasoline is a flammable item, fireworks are strictly prohibited at the work site. Not only pay
attention to open flames, but also pay attention to electric sparks. In addition, there is a danger of
explosion of vaporized gasoline. Please choose a well-ventilated site for work.
6. Be careful not to let the rear wheel, clutch and other rotating parts and movable parts clamp the
hands and clothes at any time during maintenance.
7. When two or more people work together, they must constantly greet each other to confirm safety.
Disassembly and assembly precautions

1. Parts, lubricants and greases must be recommended by Huayang brand.
2. Separate and store the parts of each system separately so that the parts can be returned to their
original positions.
3. Please clean the dirt and dust on the car before maintenance.
1-1
1 维修信息
4. The gasket, O-ring, piston pin retaining ring, split pin, etc. must be replaced with new ones after
disassembly.
5. If the opening of the circlip is too large when disassembling, it will be deformed and will fall off
easily after reassembly. Please do not use elastic circlips that are already loose and lose their
elasticity.
6. After the parts are disassembled and inspected, clean them before the measurement and blow off
the cleaning agent with compressed air. Apply lubricant to the moving surface before assembly.
7. When disassembling, check the necessary places and measure the relevant data so that it can be
restored to the state before disassembly during assembly.
8. Fasteners such as bolts, nuts and screws should be pre-tensioned and then tightened according to
the specified tightening torque on the diagonal according to the principle of being large to small and
from the inside to the outside.
9. Rubber parts should be inspected for aging when disassembled, and replaced if necessary. In
addition, since the rubber parts are not resistant to corrosion by gasoline or kerosene, try not to allow
volatile oils and greases to adhere to them.
10. Apply or inject the recommended grease at the designated location in accordance with the
requirements of the service manual.
11. The correct special tools should be used for disassembly and assembly.
12. The ball bearing can be rotated by the inner ring or the outer ring with the finger to confirm
whether the rotation is flexible and smooth. If the disassembly method of applying force on the ball
is taken during disassembly, the removed bearing should not be used any more:
Replace the bearing axial and radial clearance too large.
Rotating bearings with stuck sensation should be cleaned. After cleaning, the stuck ones should
be replaced and cannot be cleaned directly.
It is originally pressed tightly with the body or shaft diameter, and the bearing should be replaced
when the fit is not tight.
13. The bearings should be coated with oil or grease before assembly. Single-sided dust-proof
bearings should pay attention to the installation direction when assembling. Open or double-sided
dust-proof bearings should be assembled with the manufacturer's logo and dimensions facing out
when assembling.
14. When installing the rectangular retaining ring, the chamfered side should face the direction of the
force. Do not use the retaining ring that has lost its elasticity. After assembly, turn the rectangular
retaining ring to confirm that it is firmly seated in the slot.
15. After assembly, it is necessary to check whether the fastening parts are tightened and the work is
normal.
16, brake fluid and coolant will damage the painted surface, plastic parts, rubber parts, etc., do not let
it adhere to such parts, in case of adhesion, immediately rinse with water.
17. The oil seal should be installed with the side marked by the manufacturer facing outward
(without oil):
1-2
When assembling, be careful not to curl the oil seal lip and prevent the burr from scratching the
oil seal lip.
Apply grease to the oil seal lip before assembling.
18. When installing the hose parts, insert the hose into the joint root. There is a pipe clamp to install
the pipe clamp in the recessed mark of the pipe. Replace the hose without tightness during
installation.
19. Do not put dust, dirt, etc. inside the engine and the hydraulic system of the brakes.
20. The gasket material attached to the joint surface of each box of the engine should be cleaned
before assembly. The bumps on the contact surface must be uniformly removed by grinding with oil
stone.
21, The cable type should not be excessively twisted and bent. Deformed and damaged cables can
cause malfunction or breakage.
22. When assembling the cap parts, the groove must be inserted into the groove.
Engine running-in
The engine has many components for relative movement, such as pistons, piston rings,
cylinder blocks, intermeshing transmission gears, etc. Therefore, in the initial stage of its
use, it is necessary to carry out standard running-in, and the running-in can make the
moving parts adapt to each other and correct. The working gap forms a good smooth
friction surface that can withstand large loads, and the engine that has been run-in is
standardized to have excellent performance and reliability.
The recommended run-in time is 10 hours and the specifications are as follows:
0 to 10 hours: Avoid continuous operation in the state of more th an 1/2 throttle. Always
change the speed. It is not recommended to operate for a long time under a fixed throttle
position. After 1 hour of operation, cool the engine for 5 to 10 minutes; Accelerated
acceleration, the throttle change should be slow, not sudden and small, do not drag the
cargo during the running-in.
Note:
Maintenance during the running -in period according to the daily maintenance
regulations, and find out the faults in time;
After the running-in is completed, the whole machine can be ma intained after the
running-in period before entering the normal driving stage .
1.2 Vehicle identification number
1-3
1 维修信息
1 VIN on chasis
2 Vehicle name plate
3 Engine number
Model AU200
VIN L6JACMLA5G ~
Engine number F1702K ~
1
2
1-4
1 维修信息
1.3 Main parameter list
Item Parameter
Model AU200
Length（mm） 1786
Width（mm） 955
Height（mm） 1050
Wheelbase（mm） 1120
Engine model LC162FMC-2
Total displacement（ml） 200
Fuel type No.92 and above gasoline
Vehicle Dry weight (kg) 180
Number of Passenger 1 person（driver）
Maximum loading weight 1 person ＋ 60kg = 120kg
Tire Front AT23×7-10
specifications Rear AT22×10-10
Minimum ground clearance 175mm
Turning circle diameter (nearest point
3000mm
minimum turning diameter)
Starting method Electric start
Engine type Single cylinder, four stroke, air cooling
Air distribution SOHC/Chain drive
Cylinder diameter ×
62 × 58.4
stroke（mm）
Engine Compression ratio 9.7 : 1
Lubrication method Wet
Oil pump type Rotor type
Lubricating oil filter type Full flow filter rotary
No. of machine oil SAE15W-40/SF and above
Cooling air
1-4
Item Parameter
Air filter type Sponge filter
Model Plunger throttle
Throttle body
Mixing valve diameter 30mm
Fuel tank volume 9L
Clutch type Dry automatic clutch
Variable speed mode （CVT）
One forward gear, one neutral gear, one
Gear shift position
reverse gear
Transmission Shift mode / sequence Hand operation/F—N—R
system
（CVT）Stepless speed
0.95~2.8
ratio
Output type Rear axle output
Direction of rotation In the forward gear, it is clockwise from the
of Engine output rear of the vehicle.
inside 32°
Steering device Steering angle
outside 24°
front Hydraulic disc
Brake type
rear Hydraulic disc
Front wheel double rocker independent
Buffer mode Suspension method suspension, rear wheel non-independent
suspension
Frame Steel pipe welded
1-5
1 维修信息
1.4 Maintenance parameter list
Lubricating device
Item Standard limited

Change oil 800ml（No oil filter replaced）－
Engine oil
Change oil 900ml（ oil filter replaced）
capacity Full capacity 1000ml －
Only use SAE 15W/40-SE，Do not substitute or
Recommended engine oil mix different grades of engine oil, which will
cause damage to the engine and cause an
accident.
Inner and outer rotor radial
－ 0.12mm
clearance
Oil pump rotor clearance between outer rotor and
－ 0.12mm
pump body
clearance between rotor surface
0.05~0.1 0.2mm
and pump body axial
Intake system ( 05-Engine section for details)
Wheel（front and rear are the same）

vertical 0.8mm 2.0mm
Wheel pulsation
horizontal 0.8mm 2.0mm
Residual trench － 3mm

wheel
Air pressure 35kPa（0.35kgf/cm2）－
Brake system

Front brake Brake disc thickness 3.5mm 3.0mm
Brake handle stroke 2 ~ 6mm －
Rear brake
Brake disc thickness 4.0mm 3.0mm
1-6
Battery / charging device / trigger coil
Item Standard
model Permanent magnet alternator
output Three-phase full wave
Magneto-trigger coil resistance 150
Magneto no-load voltage (engine is in cold no
Magneto state)
Magneto maximum output power 180w
Stable voltage 14.5 ±0.5V
Trigger coil Max voltage ≥1V，200r/min；≥8.5V，2000r/min
Rectifier type Full wave rectification
capacity 12V 7Ah
Battery Fully charged 14.4V
Voltage between
No Fully Less than 11.8V
terminals
charged
Ignition device
Item Standard
Ignition method CDI Electronic ignition
model Resistive spark plug
standard D8RTC
Spark plug Spark plug gap 0.6~0.7mm

Spark
Blue and white light
characteristics
primary 0.3 Ω
Ignition coil
resistance Secondary 3.8 kΩ
Primary Ignition
300~450V
Max voltage coil
Pulse generator 20kV~30kV
Starting relay coil resistance 3.5 Ω
1-7
1 维修信息
Light / instrument / switch
Item Standard
fuse 10A
Headlight 12V—35W
Front turnlight 12V—10W
Light, bulb Rear light / brake light 12V—2.8W
Rear turn light 12V—2.5W
Position light 12V—3W
Valve + cylinder head ( section 05 - Engine)
Cylinder + Piston + Piston Ring + Crank Link (section 05 - Engine )
Clutch + transmission（ section 05 - Engine）
1-8
1.5 Fastener tightening torque

Note:
Put some rust-proof grease to the threaded part and the joint before installing the thread
Tightening torque at the specified part - the entire vehicle part
Tightening torque
No. Item Fastener code quantity
（N·m）
1 Suspension lower rocker bolt GB5789 M10×1.25×80 4 45~59
2 Front and rear shock absorbing bolts GB5787 M10×1.25×40 6 45~59
3 Front hub mounting slotted nut GB9457 M14×1.5×H18 2 126~218
4 Steering rod ball pin slotted nut GB9457 M10×1.25 4 33~45
5 Directional cap screw GB70-85 M8×35 4 22~30
6 Front brake caliper body bolt GB5789 M8×25 4 22~30
7 Front brake disc bolt M8×1.25×20 8 22~30
8 Rear brake caliper body bolt GB5789 M8×25 2 22-30
9 Rear brake disc mounting screw GB70-85 M8×16 4 22~30
9 Directional mounting bolt GB5783 M10×1.5×30 2 45~59
12 Oil cooler mounting bolt GB5789 M6×25 4 9~12
13 Tow ball fixing plate mounting screw GB70-85 M10×1.5×30 4 45~59
14 Rear hub mounting slotted nut GB9457 M16×1.5 2 199~311
15 Steering column mounting slotted nut GB9457 M12×1.25 1 110~130
16 Steering column clamp mounting bolt GB5787 M8×60 2 22~30
17 Fuel tank front mounting bolt GB5789 M6×25 2 9~12
18 Fuel tank rear mounting bolt GB5789 M6×30 2 9~12
19 Horn mounting bolt GB5787 M6×16 1 9~12
20 Negative pressure switch bolt GB5787 M6×16 1 9~12
21 Engine mounting bolt GB5787 M10×1.25×160 1 45~59
22 Sprocket seat mounting screws GB70-85 M8×20 4 38~51
23 Plastic base mounting screw GB70-85 M6×45 4 13~16
24 Crosshead self-tapping screws GB845-85 ST4.2 — —
25 Crosshead screw GB828-88 M5×16 2 —
26 Crosshead flat screw TM6 — —
27 Rim mounting nut GB6187-86 M10×1.25 16 45~59
1-9
1 维修信息
Tightening torque at the specified location - engine section ( section 05-Engine )

tightening torque at the unspecified location
kind Torque N·m kind Torque N·m
5mm Bolts and nuts 4.5~6 5mm Screw 3.5~5
6mm Bolts and nuts 8~12 6mm Screw 7~11
8mm Bolts and nuts 18~25 6mm Convex bolt 10~14
10mm Bolts and nuts 30~40 8mm Convex bolt、Screw 20~30
12mm Bolts and nuts 35~50 10mm Convex bolt、Screw 30~40
Engine repair tool (section 05-Engine)
Engine-specific tools (section 05-Engine)
1.6 Lubricating grease, sealant
location note Kind of grease

Steering bearing
Throttle cable connection
Rocker arm
Directional column inner Light lithium soap grease
circumference
Cushion lock active part
Shifting mechanism active part
Cables, bearings, and manipulating lubrication parts

location note Kind of grease
Steering shaft spherical bushing
Rear wheel axle supporter
Front and rear shock absorber joints Automotive universal
Throttle handle shaft and cable lubrication lithium grease
connector GB/T5671
Left and right brake handle shaft
Parking cable connection
Engine running materials and installation accessorie s（ section 05-Engine）
1-10
Engine operating materials include lubricating oil (oil), grease (butter) and coolant;
installation accessories include flat sealant, thread locker, etc.
1.7 Cable, hose, cable wiring diagram
1 2 3 4 5 6 1
1. Headlight connector 2. Left turn signal connector 3. Left hand multi-function switch
connector 4. Instrument connector 5, right turn signal connector 6, electric door lock switch
connector
Note: The front panel must be removed before inspection of the above components.
For specific disassembly,check Chapter 2 Body Covers.
11
1 维修信息
7 8 9
7, brake sensor (left one and right one) 8, throttle line 9, brake hose
1 2 3 4 5
1. Motor line 2. Crankcase exhaust pipe 3. Carburetor 4. Carburetor drain pipe 5. Magnetic
motor trigger connector
Note: The right foot pedal and the right middle guard must be removed before
inspection and maintenance of the above components.
1-12
For specific disassembly,check Chapter 2 Body Covers.
6、Voltage regulator rectifier 7, charging connector 8, relay
2 4
1 3
1、Brake light patch cord 2. Left turn signal patch cord 3. Brake light contact wire 4. Right
turn signal patch cord
1-13
2 Vehicle Body Covers

2.1 Maintenance information………………………………………………………2-2
2.2 Mounting torque………………………………………………………………2-2
2.3Disassembly of seat cushion and front/ rear shelves
2.3.1 cushion……………………………………………………………………2-3
2.3.2 front shelf…………………………………………………………………2-3
2.3.3 rear shelf……………………………………………………………………2-4
2.4 Disassembly of front panel, instrument front cover, instrument panel, gear shift
head assembly and shifting decorative cover
2.4.1 front panel…………………………………………………………………2-4
2.4.2 instrument front cover………………………………………………………2-5
2.4.3 instrument panel……………………………………………………………2-5
2.4.4 gear shift head assembly……………………………………………………2-5
2.4.5 shifting decorative cover……………………………………………………2-6
2.5 Disassembly of left middle guard , right middle guard, left pedal and right pedal
2.5.1 left middle …………………………………………………………………2-6
2.5.2 right middle guard…………………………………………………………2-6
2.5.3 left pedal……………………………………………………………………2-7
2.5.4 right pedal…………………………………………………………………2-7
2.6 Disassembly of front air duct and bumper
2.6.1front air duct…………………………………………………………………2-7
2.6.2bumper………………………………………………………………………2-8
2.7 Disassembly of fuel tank cover, front assembly plate and rear assembly plate
2.7.1fuel tank cover………………………………………………………………2-8
2.7.2front assembly plate…………………………………………………………2-9
2.7.3rear assembly plate…………………………………………………………2-9
2-1
2 车体覆盖件
2.1 Maintenance information

Precautions
When the cover on the vehicle is pasted or riveted, the warning cover shall be
correctly and completely filled with the corresponding mark when it is replaced.
This chapter describes the disassembly and assembly sequence of the body cover.
When the internal parts of the vehicle are to be removed, the relevant cover parts can
be removed. Refer to this chapter.
This chapter describes the disassembly and assembly operations of shelves, seat
cushions, and exterior parts.
Pipes and cables should be passed from the correct position according to the wiring
diagrams of cables, pipes and cables.
2.2 Mounting torque

M8 bolt 21（2.1） torque N·m(kgf·m)
M6 bolt 10（1.0） troque N·m(kgf·m)
M5 bolt 5（0.5） troque N·m(kgf·m)
Self-tapping screw 4（0.4） torque N·m(kgf·m)
2-2
2.3 Disassembly of seat cushion and front/

rear shelves
2.3.1 Cushion
Disassembly
Open the seat cushion hook upwards
Lift the back of the seat cushion and pull
the seat cushion back
Remove the seat cushion
Assembly 2
In reverse order of reverse disassembly,
reverse direction
Check if the seat cushion is in place,
1
secure, etc. after installation
1
2.3.2 Front shelf
Disassembly
Remove the front shelf mounting screws
1 (one left and one right)
Remove the mounting bolt 2
Remove the front shelf 4 2
4
Assembly
Installation in reverse order of
disassembly 3
3
2 车体覆盖件
2.3.3 Rear shelf
Disassembly
Remove the rear shelf mounting screws
1
Remove the rear shelf 4 4
Assembly 2
disassembly
3
2.4 Disassembly of front panel,

1
instrument front cover,
instrument panel, gear shift
head assembly and shifting
decorative cover
2.4.1front cover
Disassembly
Remove the front shelf (→ 2.3.2)
Remove the 2 mounting screws1
Remove the front panel2
Assembly
In reverse order of reverse disassembly, 2
reverse direction
2-4
2.4.2 Instrument front cover
Disassembly
remove the 2 screws 1
Remove the front cover of the
instrument 2
Assembly
reverse direction 2
1
2.4.3 Instrument panel
Disassembly 4
Remove the front cover of the
instrument (→ 2.4.2)
remove the 2 screws 3
Remove the instrument panel 4
Assembly
In reverse order of reverse disassembly, 3
reverse direction
2.4.4 Gear shift head assembly
Disassembly
Loosen the lock screw 5
Counterclockwise rotation gear shifter
combination 6
Unscrew the shift head combination 6
Remove the gear head assembly
Assembly
reverse direction
6 5
2-5
2 车体覆盖件
2.4.5 Shift decorative cover
Disassembly
Remove the gear shifter combination
(→ 2.4.4)
Remove 2 mounting screws 1
Remove the shift cover 2
2
Assembly
1
reverse direction
2.5 Disassembly of left middle
guard, right middle guard, left

3
pedal and right pedal
2.5.1 left middle guard
Disassembly
Remove the seat cushion (→ 2.3.1)
Remove the screw 3
Remove the left decorative panel 4 up
Assembly
reverse direction
4 6
2.5.2 Right middle guard
Disassembly
Remove the screw 5
Remove the left decorative panel 6 up
Assembly
reverse direction
2-6
Assembly
2.5.3 Left foot pedal In reverse order of reverse disassembly,
reverse direction
Disassembly 1
Remove the left middle guard (→ 2.5.1)
Remove the fastening screw 1
Remove the fixing screws 2
Remove the left foot pedal 3 from the
bottom to the top
Assembly
reverse direction
1
2 4
2.5.4 Right foot pedal 3
Disassembly
Remove the right middle guard (→
2.5.2)
Remove the fastening screw 4
Remove the fixing screws 5
Remove the right foot pedal 6 from the
bottom to the top
Assembly
reverse direction
5 6
2.6 Disassembly and assembly of

7
front ventilating panels and
bumpers
8
2.6.1 Front ventilation panel
Disassembly
Remove the mounting bolts 7 (2 on each
side)
Remove the front turn signal 8 (one on 9
each side)
Remove the front ventilation panel 9
2-7
2 车体覆盖件
2.6.1 bumper
1
Disassembly
Remove the front shelf (→ 2.3.2)
Remove the mounting bolts 1 (two on
each side)
Remove the bumper 2
Assembly
reverse direction
2.7 Disassembly of fuel tank 3
cover, front assembly plate and
rear assembly plate
2.7.1 Fuel tank cover
Disassembly
Remove the mounting screws 3
Remove the fuel tank cap
Remove the fuel tank cover 4
Assembly
In reverse order of disassembly
2-8
2.7.2 Front assembly board
Disassembly
Remove the front cover of the 1
instrument (→ 2.4.2)
Remove the front panel (→ 2.4.1)
2.5.2)
Remove the left foot pedal (→ 2.5.3)
Remove the right foot pedal (→ 2.5.4)
Remove the fuel tank cover (→ 2.7.1)
Remove the front assembly board 1
Assembly
note
Remove the cables on the front
assembly board before disassembly,
and check the cables and connectors
after installation to prevent
misconnection.
2.7.3 Rear assembly board

Disassembly
2.5.2) 2
Remove the left foot pedal (→ 2.5.3)
Remove the right foot pedal (→ 2.5.4)
Remove the fuel tank cover (→ 2.7.1)
Remove the mounting screws 2
Remove the rear assembly board 3
Assembly
note
Before disassembling, disconnect the
cable of the taillight and the rear turn
signal, and when removing the battery,
turn off the ignition switch, first remove
the positive battery, and install the
battery negative first. Check the
installed electrical appliances, cables,
etc. after installation.
2-9 3
3 Regular inspection and adjustment

Inspection………………………………………………………………………………...3-1
3.1 Determination of maintenance period…………………………………………………3-2
3.2 Inspection and repair method…………………………………………………………3-3
3.3 Direction column, brake system………………………………………………………3-5
3.4 Wheel…………………………………………………………………………………3-9
3.5 Suspension system……………………………………………………………………3-12
3.6 Shifting mechanism, fuel device……………………………………………………...3-13
3.7 Throttle check…………………………………………………………………………3-14
3.8 Meter…………………………………………………………………………………3-15
3.9 Lighting device………………………………………………………………………3-15
Maintenance information
Precautions
Note
 Because the exhaust gas contains toxic components such as carbon monoxide (CO),
do not operate the engine for a long time in a closed place or in a poorly ventilated
place.
 When the engine is just stopped, the temperature of the muffler and the engine is
still very high. If it comes into contact with the skin, it will burn. If you must
perform maintenance when the engine is just stopped, you must wear long-sleeved
overalls and gloves to work.
 Gasoline is very easy to catch fire, and fireworks are strictly prohibited in t he
workplace. Not only pay attention to open flames, but also pay special attention to
electrical sparks. In addition, due to the danger of explosion of vaporized gasoline,
the operation should be carried out in a well ventilated area.
Note
Don't let the rotating parts such as the drive system grip the hands and clothes.
Note
The vehicle must be placed in a flat, stable place on the ground.
3- 1
3 定期检查与调整
3.1 Determination of maintenance period

Engine maintenance is a regular periodic work. It is very important to maint ain the
engine at regular intervals. Standard maintenance can ensure excellent engine
performance, reliable operation, and economical and durable. The following is the
LXCVT200 engine. Maintenance schedule:
Note: The following table is designed according to normal use conditions. Under severe
conditions, the engine maintenance cycle should be shortened accordingly.
Item odometer km
Maintenance item
period 1000km 4000km 8000km 12000km note
Fuel system access I I I
Fuel filter C C C C
Carburetor choke
Air filter element note ①
Spark plug I I I I
Valve clearance I I I I
Every
Engine oil R R R R
year
Every
Lubricating oil filter C
year
clutch I I I I
Carburetor idle speed I I I I
Vehicles should be repaired according to the specified repair time. The meanings
of the various codes in the table are as follows:
C: cleaning
R: Replace
A: Adjustment
L: Lubrication
I: check
Note ①: When driving in dusty places, it should be cleaned frequently.
3-2
3.2 Inspection
Inspection and repair project period
daily Half One
Check parts Check item a year Benchmark
year
steering wheel Operational flexibility ○
steering damage ○
device steering system Steering system ○
installation status
Sloshing of the pin ○
Brake pedal Pedal stroke ○ ○
Braking effect ○ ○
Connecting rod looseness and damage
○ ○
and tubing
Braking Front/rear Brake fluid Brake fluid should be at
device volume ○ ○ the lower limit
Hydraulic (LOWER) or more
brake and If the working disc
brake disc wear and damage of thickness of the
Brake disc current brake disc is
less than 3mm and the
thickness of the
○ ○
working disc of the
rear brake disc is less
than 3mm, it should
be replaced in time.
Minimum brake pad
Brake pad wear and damage of (friction plate)
Brake pad thickness ≥ 1mm;
○ ○
replace when less than
1mm
Front wheel：35kPa（
Tire pressure 0.35kgf/ cm2）(5PSI)
○ ○ Rear wheel： 35kPa（
0.35kgf/ cm2）(5PSI)
Tire cracking and
Travel wheel ○ ○
damage
device
If there is no wear
Tire groove depth and indication on the tire
abnormal wear surface, the residual
○ ○
groove depth should
be no less than 3mm.
Loose of wheel nuts and
○ ○
wheel axles
Shaking of the front
○ ○
wheel bearing
Shaking of the rear ○ ○
3- 3
wheel bearing
Suspension Shaking of the
arm connecting part and
Buffer ○ ○
damage of the rocker
device arm
Shock absorber Oil spill and damage ○ ○
function ○
Front bridge Transmission, lubrication ○ ○
transmissi Rear bridge Transmission,
○ ○
on lubrication
Gearbox Oil leakage and oil Loosen the oil filler bolt
quantity ○ ○ port, the oil volume
should be to the top
4
Inspection and repair project period

dail Half One
Check parts Check item y a year Benchmark
year
Output shaft Loose connection ○ ○
transmissi (transmission
shaft) Splashing of the spline ○
on
Spark plug clearance ：
Status of the spark plug ○
Ignition device 0.6mm~0.7mm
Ignition period ○
Electrical Battery Terminal connection
○
installation status
Electrical Looseness and damage at ○
circuit the joint
Fuel leak ○
Throttle handle clearance：2
Fuel device Throttle status ○ ~ 6mm
Lighting device and turn
Function ○ ○
indicator
Alarm and locking device Function ○
meter Function ○
Whether the installation is
○
Exhaust pipe and muffler loose or damaged
Muffler function ○
frame Looseness and damage ○
Lubricating grease state
other ○
of each part of the frame
Confirm whether there is
The part that can confirm the
any abnormality in the ○
abnormality during operation
relevant part
5
handle.
3.3 Direction column, brake system
Place the car in a horizontal position, and
grasp the direction to check the presence or
absence of shaking in the direction shown.
If you feel shaking, check if the steering

column is shaking or other shaking and
perform the corresponding maintenance.
If the direction column is shaking, increase

the locking force of the direction column
lock nut or disassemble the direction column
for repair.
Place the car in a horizontal position and

slowly turn it to the left and right to confirm
whether it can be rotated smoothly and
flexibly. If there is any obstruction in some
places, check the main cable assembly and
the cable type for interference. If the
position of the end of the steering rod is not
observed, check for interference and
whether the steering bearing is damaged.
Note: : It must be confirmed that the
steering is flexible, otherwise the steering
handle will be accidentally unable to
control the direction.
The clearance of the front brake handle:

Operate the front brake lever to check the
brake effect and the action of the handle.
Check the clearance at the front brake
3-6
Front brake pump combination

<liquid quantity>
Check the amount of brake fluid
Check the brake fluid volume through the
observation hole 4. When the brake fluid
volume decreases to the vicinity of the lower
limit line 2 (LOWER), the vehicle will not
be able to continue to use at this time, and it
is necessary to check the brake pump, the
brake pipe and the leakage at each joint. If
the inspection is normal, you need to check
the wear of the brake disc and the brake
pads. Replace if it is damaged or worn
below the limit of use.
Inspection of these items is also required
before each use of the vehicle.
Remove the 2 vent screws 1
Remove the oil cup cover 3
Add the brake fluid recommended by 1
Huayang until the upper limit line 2
3
Note
Do not mix dust and water when
replenishing brake fluid
To prevent chemical changes, use a
specified grade of brake fluid.
Because the brake fluid will damage the
plastic surface and rubber surface, please do
not splash it on these parts.
Turn the direction handle slightly to the left
and right, and remove the oil cup cover after
the brake pump combination is in the
horizontal state.
1, exhaust screw
2, the lower limit line
3, oil cup cover
4, observation hole
4
3- 7
Front brake disc, brake pad <wearing of

brake pads>
Check the wear of the brake pads
If the wear has reached the wear limit,
replace the brake pads
Note
Brake pads need to be replaced
completely
Brake disc inspection and replacement

Check the sliding surface of the brake disc 1
for wear and damage. If the current brake
disc thickness is ≤ 3.0mm, replace the
brake.
Front brake disc limit thickness for use：

3.0mm
1
Check the minimum thickness of the brake

lining 2
Minimum friction plate thickness ≥ 1 mm
If it is less than the minimum friction plate
thickness, please replace it with a new brake
friction plate.
Check the brake lining for damage or cracks.
If there is any damage or crack, please
replace it with a new brake lining.
Note: Please check the position of the

brake fluid level frequently, keep the
liquid level in a safe position, check the oil
circuit and connection points for damage,
if any, please replace it in time, check the
main pump / caliper for damage, if any,
please replace it in time.
Note: Do not open the brake fluid cup for
a long tim 2
Oil change <replacement of brake fluid>

Brake fluid is replaced once a year
3-8
Rear brake pump combination <liquid

volume>
Check the amount of brake fluid
Check the brake fluid volume through the 1
observation hole 4. When the brake fluid
volume decreases to the vicinity of the lower
limit line 2 (LOWER), the vehicle will not
be able to continue to use at this time, and it
is necessary to check the brake pump, the
brake pipe and the leakage at each joint. If
the inspection is normal, you need to check
the wear of the brake disc and the brake
pads. Replace if it is damaged or worn
below the limit of use. Inspection of these
items is also required before each use of the
vehicle.
Remove the 2 vent screws of the oil cup
cover 1
Remove the oil cup cover 3
Add the brake fluid recommended by
Huayang until the upper limit line 2
 Do not mix dust and water when

replenishing brake fluid.
 To prevent chemical changes, use a
specified grade of brake fluid
 Because the brake fluid will damage the
plastic and rubber surfaces, do not spill
them on these parts.
Note: Please check the brake fluid level

frequently, keep the liquid level in a safe
position, check the oil circuit and
Check the connection point for damage. If
it is available, please replace it in time.
Check the main pump/caliper for damage.
If it is, please replace it in time.
Note: Do not open the brake fluid cup for
a long time.
3- 9 4
Rear brake disc, brake pad <wearing of

brake pads>
Check the wear of the brake pads
If the wear has reached the wear limit,
replace the brake pads
note
Brake pads need to be replaced
completely
Brake disc inspection and replacement

Check the sliding surface of the brake disc 1
for wear and damage. If the current brake
disc thickness is ≤ 3.0mm, replace the
brake disc.
Rear brake disc limit thickness for use:

3.0mm 1
Check the minimum thickness of the brake

lining 2
Minimum friction plate thickness ≥ 1 mm
If it is less than the minimum friction plate
thickness, please replace it with a new brake
friction plate.
Check the brake lining for damage or cracks.
If there is any damage or crack, please
replace it with a new brake lining.
Oil change <replacement of brake fluid>

Brake fluid is replaced once a year
2
3-10
3.4 wheel
Lift the front wheel with the tool in the
horizontal position, make sure that the car
body has no force on the wheel, shake the
front wheel from side to side, check whether
the front wheel connection is firm, check for
shaking.
If there is any shaking, check and tighten the
rocker arm, axle, rim bolt, nut.
If there is still shaking, check and replace:
bearing, rocker buffer sleeve, ball pin.
Front wheel size

The vehicle body is placed in a horizontal
position, and the toe size of the wheel is
measured; the front of the wheel with
respect to the forward direction of the
vehicle is: A, and the rear of the wheel is: B
Toe size: A-B=1.5 ~ 2.5mm
F is the way forward 1
If not in this range, adjust the lock nut2 of

the steering rod 1
Note: After the front beam size is adjusted,
drive the vehicle slowly and make sure
that the handlebar can correctly control
the direction of the motor body.
3-11
Tire pressure
Check the tire pressure using a barometer
Note
The tire pressure is checked while the tire is
cool. If it is used in a state where the tire air
pressure is not suitable, it will deteriorate the
operation and ride comfort, and cause
adverse effects such as eccentric wear of the
tire.
Specified air pressure / tire
Front tire Rear tire

Air pressure 35kPa（0 .35kgf/cm ） 2 35kPa（0.35kgf/cm2）
size See Chapter 1 See Chapter 1
Tire pattern
Check the tread pattern and replace the new
tire once the pattern height is less than 3mm
note
When the tire pattern is less than 3mm, it
must be replaced immediately
3-12
Wheel nut and wheel axle

Check the front axle, rear axle nut 1 and the
looseness of the latch
Fasten at specified torque when loose
Torque:
Front axle nut: 126N·mm～218N·mm
(12.6kgf·mm to 22kgf·mm) 1
Rear axle nut: 199N·mm~311N·mm
(20kgf·mm to 31kgf·mm)
Shaking of wheel hub

Use the tool to frame the front wheel. When
the car body does not exert force on the
front wheel, shake the wheel axially to
check for shaking.
Remove the front wheel when shaking,

check the wheel hub
3.5 Suspension system
Place the motor body in a horizontal position and press the motor body up and down several
times according to the position shown. If there is any sway or abnormal noise, check the
shock absorber for oil leakage, damage to each fastening part, looseness, etc.
13
Shock absorber adjustment
Adjusting the adjustment cam 1 of the shock

absorber according to the load with a special
tool
Clockwise rotation is from high to low,
counterclockwise rotation is adjustable from
low to high bidirectional
3.6 Shifting mechanism, fuel device

2
Shifting mechanism
Replace the gear position, check whether the
shifting mechanism2 is flexible, and whether
the gear position is in the gear. If the gear
shift is not flexible, adjust the length of the
shifting mechanism tie rod 3.
Loosen the lock nut 4 and adjust the length
of the shifting mechanism lever
Fuel device
Fuel system status
Check the fuel pipe for aging and damage.
When the fuel pipe is aging or damaged,
replace it with a new one. 4
Check the fuel tank vent pipe or the fuel 3
evaporating system for rupture and bending.
If there is any damage, replace it with new
ones.
3-14
3.7 Throttle check
Check the free stroke of the throttle button 1

Clearance: 2 ~ 6 mm
1
Adjust the clearance when the clearance is

not within the specified range 3
Remove the sheath 3
Release the throttle cable lock nut 2
Turn the adjuster to adjust the free travel of
the throttle button
After adjustment, tighten the lock nut 2 to 2
install the throttle cable sheath 3
If the adjustment regulator still does not
reach the specified clearance or the
movement is still not flexible, replace the
new throttle cable.
Speed limit device adjustment

The speed limit device is used to limit the
opening of the throttle
Check the thread limit length of the speed
limit screw 4,
Thread limit length: a = 12mm
Adjustment method
Loosen the lock nut
Adjust with a Phillips screwdriver
Note: For beginners, the speed limit
device should be in a tightened state, and 4
the speed limit device can be used to
change the throttle size after the
technology reaches a certain level.
In addition, 12mm is the limit length of
the speed limit device thread. Generally,
this length is only adjusted to 3mm~5mm.
3-15
3.8 Meter
Check meter
When the vehicle system is powered on for
the first time (or after the instrument is 1
replaced for the first time), when the engine
is not working, the speed should be in the
zero position, start the engine, pay attention
to whether the speed value indicates change,
if it does not change, it should be repaired in
time.
3.9 Lighting device

Front light axis adjustment
(Take the right front headlight as an example)
Adjust the bolt with a “Ten”screwdriver or
wrench 1. Adjust the low beam; adjust the
bolt 2 to adjust the up and down direction of replace the tail light in time.
the headlight. Horn check
Hold down the horn switch 4 and observe
Note: The vehicle system requires power the horn. If the horn is not loud or the sound
before checking the lighting unit. is too light, please check if the line is
Turn signal inspection connected incorrectly. If the wiring is
Turn the turn signal switch 3 to the left and correct, please replace the horn in time.
right respectively to observe whether the
front and rear turn signals of the vehicle are
on. If it is not bright, please check if the line
is connected incorrectly. If the wiring is 3
correct, please replace the turn signal in
time.
Taillight inspection
Hold the brake lever with your hand and
observe the tail light. If the tail light is not
bright, please check if the line is connected
incorrectly. If the wiring is correct, please
4
3-16
4 发动机周边
4 Engine periphery
Maintenance information……………………………………………………………4-1
4.1 Fuel System……………………………………………………………………4-2
4.2 Intake system……………………………………………………………………4-2
4.3 Exhaust system…………………………………………………………………4-3
4.4 Engine disassembly and installation……………………………………………4-5
precautions
 When repairing the operation, please ensure that the vehicle is turned off and left
still for less than 1 hour, and confirm that the heating parts are cooled before
performing maintenance to avoid injury to maintenance personnel.
 Be careful not to damage the frame, engine body, bolts, cables during operation.
 When the engine is disassembled, the frame should be protected against the
frame.
 When the engine is removed, in order to protect the environment, the
corresponding container should be filled with coolant, oil and fuel. When
installing, the coolant and oil should be replenished as required.
Tightening torque
Engine mount mounting bolt GB5787 M10×1.25×160 45~59N·m
2
4.1 Fuel System 1

Disassembly
Remove the seat cushion, fuel tank
cover, instrument front cover, front
assembly plate ( → Chapter 2 Body
Cover)
Release the oil level sensor connector 3
Remove the oil pipeline 4 (connected to
the carburetor)
Remove the fuel tank 2
Note
Gasoline is very easy to catch fire, so 2
fireworks are strictly prohibited in the
workplace.
Not only open flames, but also high
attention to electric sparks
In addition, due to the danger of 3
explosion after evaporation
(vaporization) of gasoline, work should
be carried out in a well ventilated area.
When disassembling the fuel tank, if
there is still fuel in the fuel tank, the oil
pipeline 4 should be tightened
beforehand to prevent fuel leakage and
then remove the fuel tank.
4
Installation
disassembly
The connector is required to be plugged
into place and there is a noticeable
"click" when installed.
The installation process checks the
integrity of each tubing.
4-3
4 发动机周边
1
4.2 Intake system 4

Disassembly
Remove the seat cushion and rear
.
2
assembly panel ( → Chapter 2 Body
Cover)
2
Remove the mounting bolts 1 (one for
each of the left and right)
Release the clamp2
Remove the carburetor 3
I
n
3
t
a
4
Remove the fuel tank (→4.1 Fuel tank
k
disassembly and safety)
Loading)
e
Remove the 2 mounting screws 4
Release the clamp5
5
Remove the intake pipe 6
Remove the crankcase exhaust pipe 7
s
Remove the air filter 8
y
Installation
s
disassembly
t
e
6
m
7
D 8
i
s
a
s
s
e
m
b
l
y
4-4 R
e
m
o
4.3 Exhaust system

1
Disassembly
cover, instrument front cover, front
assembly plate, rear assembly plate (→
Chapter 2 Body Cover)
Remove 2 bolts 1
Remove the insulation2
3
Remove the mounting nut 3
Remove the muffler barrel mounting

bolt 4
Remove the exhaust pipe assembly 5
installation
Installation is in reverse order of
disassembly
5 4
4-5
4 发动机周边
4.4Engine disassembly and
installation
Disassembly
3
cover, instrument front cover, left
middle guard, right middle guard, left
foot pedal, right foot pedal (→ Chapter
2 Body Cover)
Remove the fuel tank ( → 4.1 Fuel
System)
Remove the air filter and carburetor (→
4.2 Intake System)
Remove the exhaust pipe assembly (→
4.3 exhaust system)
4
Remove 3 bolts 3
Remove the engine left cover 4
Remove the bolt 5

Disengage the shifting assembly 6 from
the engine
Remove the chain 7
7 6 5
4-6
Remove the spark plug cap 1

Remove the throttle tube connector 2
3 4
Remove the magneto motor trigger 5
patch cord 3
Remove the charging patch cord 4
Remove the crankcase exhaust pipe 5
Remove the motor cable 6 (Remove the
6
screw at the relay)
Remove the carburetor drain pipe 7
8
Remove the mounting bolts 8
Remove the fixing piece 9
Remove the engine 10
installation
disassembly
9
10
0
4-7
5 Engine
5.1 Overview…………………………………………………………………………………5-2
5.2 Lubrication system………………………………………………………………………5-6
5.3 Check and adjust…………………………………………………………………………5-8
5.4 Fuel System……………………………………………………………………………5-12
5.5 Cylinder head and valve………………………………………………………………5-17
5.6 Cylinder and piston……………………………………………………………………5-30
5.7 Oil pump………………………………………………………………………………5-35
5.8 Right crankcase cover and magneto……………………………………………………5-38
5.9 CVT parts…………………………………………………………………………….5-40
5.10 Crankcase, crankshaft, variable speed drive…………………………………………..5-43
5.11 Fault judgment………………………………………………………………………..5-50
5- 1
5 发动机
5.1 Overrview
Maintenance
precautions……………………………………………………………………………5-2
5.1.1 Main performance technical parameters………………………………………………5-3
5.1.2 Mark torque data……………………………………………………………………5-4
5.1.3 Maintenance schedule…………………………………………………………………5-5
Maintenance precautions
1、Parts, lubricants or other auxiliary materials produced or approved by Chongqing Longxin

Group shall be used. If the materials used do not meet the “Loncin” specifications or
requirements, the motorcycle may be damaged;
2. When reassembling after disassembly, replace gaskets, seals and cotter pins;
3. When tightening bolts or nuts, it should be carried out in the order of diagonal crossing, and
gradually tighten to the specified torque in 2~3 times;
4. When cleaning parts, use cleaning liquid that cannot burn or high ignition point. Lubricate
the sliding surface of the part before assembly;
5. After assembly, check whether the parts of each part are installed correctly, and perform
rotation, movement and inspection operations.
5- 2
5.1.1 Main performance technical parameters

item data
model LC162FMK–2
type Ignition
Cylinder arrangement Vertical
Cylinder diameter × 62×58.4
stroke
Working volume Basin type combustion chamber，17.8ml
Compression ratio 9.7:1
Maximum power and 9kw/8000r/min
Engine corresponding speed
Maximum torque and 13N•m/6000r/min
corresponding speed
Minimum fuel 354g/kw•h
consumption rate
Valve clearance (when Intake and exhaust 0.06mm
cooling)
Engine static mass 39kg
Idle speed 1700r/min
clutch Continuously variable speed
Secondary reduction 2.14
Transm ratio
ission Stepless transmission 0.95~2.8
system ratio
Form of Shift change Non-cyclic shift
Starting device Electric start
Ignition method CDIElectronic ignition
Electri generator Permanent magnet alternator
cal Battery capacity 12V7Ah
system Spark plug model D8RTC
Spark plug gap 0.6~0.7mm
5- 3
5 发动机
5.1.2 Mark torque data

Thread
Item quantity Torque N•m
diameter
Cylinder head cap fastening bolt 4 6mm 10~14
Cylinder head fastening nut 4 8mm 23~30
Magneto motor rotor fixing bolt 1 8mm 45~53
Primary active tooth lock nut 1 16mm 40~50
Oil filter cover nut 1 36mm 10~20
Shift drum positioning plate bolt 1 6mm 8~12
Shift drum and dial connecting
1 6mm 8~12
bolt
Cylinder head nut 4 8mm 28~30
In addition to the torque values of the important parts listed in the above table, the torque
range of the other fasteners is as follows：
Name and size (thread diameter) Torque N•m

5mm Bolts and nuts 4.5~6
6mm Bolts and nuts 8~12
5mm Screw 3.5~5
6mm Screw 7~11
6mm Bolt and nut 10~14
5- 4
5.1.3 Maintenance schedule
item Mileage（km）
times
Maintenance item
period 1000 4000 8000 12000 note
Fuel system
☆ I I I
access
☆ Fuel filter C C C C
☆ Carburetor choke
Air filter element Note①
Spark plug I I I I
☆ Valve clearance I I I I
Per
Engine oil R R R R
year
Lubricating oil Per
C
filter year
☆ clutch I I I I
Carburetor idle
☆ I I I I
speed
The vehicle should be repaired according to the specified repair time. The meanings of
the various codes in the table are as follows:
C: cleaning
R: Replace
A: Adjustment
L: Lubrication
I: Check and, if necessary, clean, replace, adjust or lubricate
☆：The project is repaired by the personnel of the Longxin service station. If you check it
yourself, you should also refer to this manual.
☆☆： For this project, this manual is recommended to be repaired by personnel at the Longxin
service station to ensure safety.
note①：Driving in dusty areas should be cleaned frequently.
5- 5
5 发动机
5.2 Lubrication system

Maintenance instructions……………………………………………………………………5-6
5.2.1 Troubleshooting………………………………………………………………………5-6
5.2.2 Engine lubrication system……………………………………………………………5-6
5.2.3 Lubricating oil inspection……………………………………………………………5-7
5.2.4 Lubricating oil replacement……………………………………………………………5-7
5.2.5 Lubricating oil filter cleaning…………………………………………………………5-7
5.2.6 Lubricating oil filter cleaning…………………………………………………………5-7
Maintenance instructions
This section describes the engine lubrication system and the cleaning, inspection, and
replacement of various parts of the system. The engine should not be removed when
inspecting and cleaning the lubrication system, but the oil in the engine should be drained
before inspection and cleaning.
5.2.1Troubleshooting
First, the lubricant is consumed too fast 2, the oil filler thread is damaged
1. The engine has oil leakage Third, the lubrication is not normal
2, piston ring wear 1, the oil level is too low
3, the intake and exhaust valve guides 2, oil passage or filter blockage
wear 3, the oil pump is damaged.
4. The oil hood is worn or damaged
Second, the lubricant is not clean

1. The engine oil is not replaced
according to the maintenance schedule.
5.2.2Engine lubrication system

Lubricating oil is an important factor different regions and temperature changes.
affecting engine performance and life. It When replacing the lubricating oil, please
must be selected according to regulations. put out the original lubricating oil in the
It cannot be replaced by ordinary engine crankcase, clean it with washing kerosene,
oil, gear oil, vegetable oil, etc. and then add new lubricating oil
When the car is shipped from the factory, according to the regulations
it is filled with 15W/40SE gasoline engine
oil. If you switch to other lubricants (the
best oil for Longxin), the quality grade
should reach QE or SF. The viscosity
should be selected according to the
5- 6
then stopped. Then, keep the body

5.2.3 Lubricating oil inspection flat and check the oil level of the oil
dipstick. At this time, the oil level
Park the motorcycle on a flat surface and check the must reach the lower line and check
amount of oil with a dipstick 1. If the oil level is lower for oil leakage.
than the lower score line, the recommended lubricant
should be replenished to fill the upper line.
4：Transmission case oil hole sealing
screw plug
5.2.4 Lubricating oil replacement
When changing the oil, it should be done before

the engine is warm and not cooled. This will ensure that
the oil in the tank is quickly and completely removed.
When replacing, turn on the oil filter cover 2 (bottom of
the crankcase), remove the spring and filter, release the
oil in the crankcase, and then unscrew the gearbox drain
screw 3 to get out the oil in the gearbox
5.2.5 Lubricating oil filter cleaning

Clean the filter with a detergent. Install the filter and
spring, install the filter cover, and tighten according to
the specified torque value. Add new lubricant from the
fill port (0.9 L crankcase, 0.4 L gearbox)
Install the screw plug with the dipstick. Then, the engine
was started to operate after idling for 45 minutes and
3
7
5 发动机
Upper line
1 Lower line
4
5.3 Inspection and adjustment
5.3.1 skills requirement………………………………………………………………………5-8
5.3.2 Spark plug……………………………………………………………………………5-9
5.3.3 Valve clearance………………………………………………………………………5-9
5.3.4 Ignition timing………………………………………………………………………5-10
5.3.5 Carburetor idle speed…………………………………………………………………5-11
5.3.6 Cylinder compression test………………………………………………………………5-11
This section describes the inspection and adjustment of various parts of the LXCVT200
engine. At the same time, the technical requirements for adjustment and inspection are introduced.
For details on the inspection of the lubrication system, see 5.2
5.3.1 skills requirement
Recommended spark plug D8RTC
Spark plug gap 0.6~0.7mm
Intake valve 0.06mm

Valve clearance
Exhaust valve 0.06mm
Before the stop point 15°±2°
Ignition advance angle （2000±200r/min）
Before the stop point 35°±2°
8
（3800±200r/min）
Idle speed 1700 ±170r/min
Cylinder compression force 1450 ±145kPa
5.3.2 Spark plug Remove the viewport cover and top

viewport cover
Use a socket wrench to remove the spark plug Rotate the magneto flywheel
and visually inspect the spark plug insulator for counterclockwise to align the “T”
damage. Whether the electrode is ablated, if any, it mark on the flywheel with the
should be replaced indicator mark on the left front cover.
Note that the piston must be at the top
Check the electrode gap with a thick gauge, the dead center of the compression stroke.
spark plug electrode gap is 0.6~0.7mm
Gap 0.6-0.7mm
Carefully adjust the gap. Then use a spark plug

cleaner or wire to clean carbon and dirt Check gap &
deposition
Electrode corrosion
When installing the spark plug, first screw the Check if gaskets
spark plug into the hand and tighten it, then cover the are sealed
spark plug cap.
Clean: Use spark
plug cleaner or
steel wire
5.3.3 Valve clearance
When installed, tighten

Note: When adjusting the valve clearance, the engine 1/2-3/4 with your fingers
should be in a cold state (temperature below 35 °
C）
9
5 发动机
Indicator
mark
T mark
Use a gauge to insert the adjustment screw and

check the clearance between the valve stem If the “F” mark on the magneto rotor is
aligned with the indication mark on the left
Valve clearance: intake valve: 0.06mm front cover, the timing is correct.
Exhaust valve: 0.06mm Idle speed is 1700 ± 170r/min
Then, increase the speed of the transmitter and
check the following items:
2000 ± 200r/min
Advanced start
3800 ± 200r/min
When adjusting, loosen the lock nut and turn Leading ahead (the indicator should be before
the adjusting screw until the gauge feels the advance sign)
slightly pulled. Then adjust the screw with the
Valve adjustment bolt
valve adjuster, then tighten the lock nut
Check the valve clearance again
Then, install the valve cover
Install the fuel tank and cushion.
5.3.4 Ignition timing
Note: The ignition timing cannot be adjusted.

Because CDI (capacitor discharge ignition)
cannot be adjusted. If the ignition is not
correct, check the CDI igniter, pulse trigger
and magneto, and replace the faulty electrical
device.
Remove the top view cover

Connect the timing light
Start the engine and put it in an idle state
10
5.3.5 Carburetor idle speed
Note: After adjusting other items of the

engine to the specified range, check and
adjust the idle speed of the carburetor.
When adjusting, the engine should be in a hot

state, support the main bracket, and rotate the
plunger adjustment screw
Idle speed：1700 ±170 r/min
Indicator
mark
T mark
Increase
Decreas
e
Throttle Valve Screw
Pressure gauge
and fully open the choke and throttle switch,

5.3.6 Cylinder compression test and start 4 to 6 times.
Warm up the engine, then turn off the engine,
remove the spark plug, then install the Note: Check the connection of the pressure
pressure gauge at the spark plug installation, gauge for leaks. The engine is continuously
5-11
5 发动机
started until the pressure gauge stops rising.

The maximum reading usually arrives after 4
to 6 starts.
Cylinder compression force：1450 ±145kPa
5.4 Fuel System

5.4.1 trouble clearing………………………………………………………………………5-12
5.4.2 Carburetor disassembly………………………………………………………………5-13
5.4.3 Throttle plunger………………………………………………………………………5-13
5.4.4 Float, float needle, nozzle……………………………………………………………5-14
5.4.5 Float height adjustment………………………………………………………………5-15
5.4.6 Throttle plunger assembly……………………………………………………………5-15
5.4.7 Carburetor installation…………………………………………………………………5-16
5.4.8 Air conditioning screw adjustment……………………………………………………5-16
1. When using gasoline, special care should be taken. Always remember to carry out in a
well-ventilated environment in the air, and keep away from sparks and flames;
2. When disassembling all parts of the fuel system, pay attention to the installation position of the
“O” ring. When reassembling, it must be replaced with a new “O” ring;
The oil drain screw at the lower end of the float chamber can loosen the screw and drain the
gasoline remaining in the float chamber.
5.4.1 trouble clearing
12
the engine can ignite, but can not start

1. There is no fuel in the fuel tank. Loosen the hook screw with the air filter.
2. No fuel enters the carburetor Then remove the carburetor cover and pull the
3, too much fuel into the cylinder throttle plunger out.
4, air filter blockage Remove the carburetor.
Note: Flames or sparks should not be close

the mixed gas is too dilute to gasoline; if spilled gasoline, it should be
1. Carburetor nozzle blockage wiped clean immediately.
2. The fuel tank cover vent is blocked
3, fuel filter blockage
4, fuel pipe flow is not smooth
5, the float needle is faulty
6. The oil level in the carburetor is too low
5.4.3 Throttle valve plunger
the mixed gas is too concentrated
1. The choke is closed
2. The oil level in the carburetor is too high
3, carburetor air nozzle blockage
4, the float stuck or the float needle is faulty
5, the air filter is not clean Remove the connection of the throttle handle
line end in the groove on the throttle valve
the idle speed of engine is unstable plunger, and press the throttle valve spring
1. Improper adjustment of idle speed when disassembling.
2, the mixture is too rich Remove the oil needle retaining ring and then
3, the mixture is too thin remove the oil needle and the oil needle
4, the cylinder compression force is too low retaining ring from the throttle valve plunger.
5, the air filter is blocked Check the surface of the throttle valve plunger
6, fuel storage for too long and the needle for cleanness, smoothness,
Impurities in the fuel scratches or wear.
5.4.2 Carburetor disassembly Connecting band screw
Turn off the fuel switch and remove the fuel

line connection. Remove the side covers on
both sides.
Loosen the carburetor drain screw and release
the fuel from the carburetor.
Remove the connecting nut of the carburetor
and the intake pipe.
5-13
5 发动机
Remove the connecting screw and float

cover of the float chamber cover.
Then pull the float arm pin out.
Remove the float and float needle.
Check the contact surface of the float needle

for wear and damage. Replace the new float
needle when necessary.
Remove the main orifice, foam tube nozzle,

idler orifice and plunger locking screw.
Remove the positioning screw.
Note: Before remove the screw, first

Valve plunger
determine the mounting position of the
screw. Remember the times of turning when
removing; otherwise, it will cause
unnecessary trouble when installing the
positioning screw.
Then clean all the channels and surfaces of

the carburetor with a cleaning solution. After
cleaning, all the channels are blown with
compressed air. Remove dirt, etc.
Plunger Spring Then, install the idler orifice, foam tube
nozzle, main orifice and plunger locking
screw in the order of disassembly; reinstall
the positioning screw and screw it to the
mounting position before disassembly.
Clip Set the opening position of the screw and
Plunge Needle
screw it back in the 7/4 turnn
r
5.4.4 Float, float needle, nozzle Float arm pin
5-14
First measure the height of the float with an

altimeter
Float height：15 ±1 mm
Float
When you need to adjust the height of the

float, slowly change the angle of the float
arm until the tip of the float arm just touches
the float needle. You can also adjust the
height of the float on the float height
detector.
Float Pin
5.4.6Throttle valve plunger
assembly
Idle speed adjustment screw
First install the retaining ring in the groove

of the oil needle
Standard positioning position: third ring

groove
Then insert the oil needle into the plunger

Foam tube
and attach the retaining ring. Then, insert the
plunger spring into the end of the throttle Retaining Rin
Idle fine-tuning
line. Connect the steering line to the throttle
screw valve plunger.
Plunger trimming screw
5.4.5Float height adjustment

5-15
5 发动机
5.4.7 Carburetor installation
Install the throttle valve plunger into the

carburetor body.
Note: The groove of the throttle valve

plunger should be aligned with the
locking screw on the carburetor body.
Then tighten the end cap of the top of the

carburetor
After installing the carburetor, adjust the
free stroke of the throttle handle with the
adjustment device on the throttle control
line.
Free stroke of the throttle handle: 2~6mm
Float 5.4.8Air conditioning screw

Assembly
adjustment
Rotate the locking screw clockwise until it

contacts the screw seat
Third ring groove Then turn in the opposite direction until the
standard position is reached.
Standard position of the locking screw: 7/4
turn
Note: If the locking screw and the screw

hole seat are tightened too tight, the screw
hole seat may be damaged.
Throttle Valve Screw
5-16
Throttle Valve Screw Decre

e
Start the engine to warm up to the operating

temperature
Adjust the throttle locking screw to achieve
idle speed
1700 ± 170r/min
Constantly manipulate the throttle hand
Check if the engine can accelerate or
decelerate steadily
Then adjust the positioning screw until the
maximum speed is reached; then, adjust the
plunger locking screw to reach the idle
speed to 1700 ± 170r/min
Increase
Decrease
Throttle Valve Screw Decreas

5.5 Cylinder head and valve Increase e
Maintenance instructions…………………………………………………………………5-17
5.5.2 Disassembly of cylinder head cover…………………………………………………5-19
5.5.3 Analysis of Rocker arm support……………………………………………………5-19
5.5.4 Camshaft removal…………………………………………………………………5-20
5.5.5 Cylinder head removal………………………………………………………………5-20
5.5.6 Camshaft inspection…………………………………………………………………5-21
5.5.7 Rocker arm inspection………………………………………………………………5-21
5.5.8 Rocker shaft inspection………………………………………………………………5-21
5.5.9 Decomposition of cylinder head……………………………………………………5-22
5.5.10 Inspection of valves and valve guides………………………………………………5-22
5.5.11 Cylinder head inspection…………………………………………………………5-23
5.5.12 Valve spring inspection…………………………………………………………5-23
5.5.13 Valve guide replacement…………………………………………………………5-23
5.5.14 Valve seat inspection and grinding…………………………………………………5-24
5.5.15 Cylinder head assembly……………………………………………………………5-27
5.5.16 Cylinder head installation…………………………………………………………5-28
5.5.17 Cylinder head cover installation……………………………………………………5-29
5-17
5 发动机
The camshaft lubricant is injected into the cylinder head via a control orifice on the engine
casing. This control orifice must not be blocked.
When assembling, apply molybdenum disulfide lubricant on the cam bearing as the basic
lubrication.
Fill the cylinder head cylinder with clean engine oil for lubrication of the camshaft.
Specifications
Item standard（mm） Maximum（mm）
Intake 31.78 ±0.06 31.4

Camshaft Cam lift
exhaus
31.53 ±0.06 31.13
t
inner diameter 12.000~12.018 12.05
Rocker
shaft Outer diameter 11.972~11.987 11.93
Outer
45.5 45.5
Valve layer
length
spring Inner
39.4 39.4
layer
Item standard（mm） Maximum（mm）
Valve clearance 0.06 —
Intake 5.45~5.465 5.42

Valve stem outer
diameter exhaus
5.430~5.445 5.40
t
valve Intake 5.475~5.485 5.53
Valve guide inner
diameter exhaus
5.475~5.485 5.53
t
Clearance Intake 0.01~0.035 0.06
between Valve
exhaus
stem and guide 0.03~0.055 0.07
t
Distortion — 0.1
Cylinder
head
Valve seat line width 1.1~1.3 1.5
5-18
5.5.1 Troubleshooting
Low cylinder pressure

1、Valve
Valve clearance adjustment is incorrect
Valve seal is not strict Remove the connecting bolts that secure the
The timing of the valve is wrong. cylinder head 1
Valve spring break Remove the cylinder head cover 2
2, cylinder head
The spark plug is not tightly connected
to the cylinder head
Leakage or damage to the cylinder head
gasket
5.5.3 Disasembly of Rocker arm
Cylinder head has cracks or blisters
3, cylinder, piston
support
Piston ring clearance too big or broken
Remove the cylinder head cover 2
The piston is cracked or damaged Remove the Ab bolt fastening nut 3 , copper
The inner diameter of the cylinder is washer 4 and steel washer 5
too large or has a blisters Remove the rocker support 9
Remove the rocker shaft limit plate
Exhaust has blue smoke Insert the threaded end of the rocker with a
1.Valve guide wear 6mm screw
2. The oil shield is leaking or damaged. Pull out the rocker shaft 8
3, cylinder head gasket leakage
4, the piston ring clearance is too big Note: nuts and washers cannot fall into
Too much noise the crankcase when disassembling。
1.Valve adjustment is incorrect
2. The valve is stuck or the valve spring is
broken. 6:Rocker arm
3, camshaft or rocker arm wear 7: rocker shaft baffle bolt
4, timing chain is too long 10: exhaust rocker shaft
5, the timing of the gas is not correct 11: intake rocker shaft
6. Timing chain tensioner is worn or
damaged
7, timing sprocket tooth wear
5.5.2 Disassembly of cylinder head
cover
5-19
5 发动机
1
5.5.4 Camshaft removal
Remove the tensioner sealing bolt 1

Remove the tensioner fastening bolt 2
Remove the tensioner
Remove the camshaft 3
Note: Do not allow the timing chain to fall

into the crankcase
2
3 4
6 7
5.5.5 Cylinder head removal
8 Remove the cylinder connection bolt 4

9
Remove the cylinder head 5
10 11
0
5-20
5.5.6 Camshaft inspection

1
Check the lift distance of each cam

Use a micrometer to measure the length
2
3 of the convex portion of the cam to check
for wear.
Maintenance limit
Intake: 31.4mm
Exhaust:31.13mm
5.5.7 Rocker arm inspection
Check the rocker for wear, damage or oil

hole blockage
Note: If any rocker arm needs to be

maintained or replaced, the unevenness of
the camshaft protruding part should be
checked accordingly.
3
Cylinder head
Measuring the inner diameter of the
rocker arm
Maintenance limit: 12.05mm
5.5.8 Rocker shaft inspection
4
Check the rocker shaft for wear and
scratches
Measuring the outer diameter of the rocker
shaft with a micrometer
The maintenance limit clearance value of the
5 rocker shaft and the hole is 0.08mm.
5-21
5 发动机
5.5.9 Decomposition of cylinder
head
Press the valve spring with a valve remover

Remove the valve lock clip
Then relax the valve remover
Remove valve spring seat, valve spring and
valve
Note: In order to prevent permanent
deformation of the valve spring, the valve
spring cannot be compressed excessively,
only the valve lock clip can be removed.
All parts removed should be marked to
ensure that the original assembly position is
reached during assembly
5.5.10 Inspection of valves and
valve guides
Check if the valves are bent, and the burns

or valves are abnormally worn.
Check the movement of the valve in the
valve guide and measure its outer diameter
Maintenance limit:
Intake: 5.42mm
exhaust：5.40mm
And insert each valve into the valve guide

to observe its movement
Measure the inside diameter of each valve

guide with an internal micrometer or a
dedicated measuring tool. Finally calculate
the gap between the valve guide and the
valve guide
Maintenance limit clearance:
Intake: 0.12mm
exhaust：0.14mm
5-22
Note: Before measuring the inner

diameter of the valve guide, the carbon
deposit in the conduit should be
completely removed.
If the valve guide needs to be replaced, the
valve seat should be reground.
Completely remove the carbon deposits in
the combustion chamber
Remove the residue on the cylinder head
plane with a spatula.
Note: The cylinder head plane cannot be
damaged. If the cylinder head and gasket
are immersed in the cleaning agent, the
gasket will be damaged.
5.5.11 Cylinder head inspection
Check the spark plug hole and valve for

cracks; check whether the cylinder head is
deformed.
Check the flatness of the cylinder head
with a knife-edge ruler and a feeler
Maintenance limit：0.1mm
5.5.12 Valve spring inspection
Measuring the free height of the inner and

outer springs of the valve
Maintenance limit: (intake and exhaust)
Outer spring: 45.5mm
Inner spring：39.4mm
5.5.13 Valve guide replacement
Fix the cylinder head

Use the valve guide removal tool to remove
the valve guide from the valve hole
Note: Do not damage the cylinder head

when removing the valve guide.
5-23
5 发动机
On the cylinder head, press the new valve

guide and the “O” ring. Then reaming the
newly installed valve guide
Note: When reaming, apply cutting oil to

the reamer. Rotate when loading or
unloading the reamer.
Finally, the cylinder head is cleaned with a

cleaning agent and all the metal chips
accumulated on the cylinder head are
removed with compressed air.
Combustion Chamber
5.5.14 Valve seat inspection and
grinding
First, remove the dust on the intake and

exhaust valves.
Apply abrasive to the valve seat
Then use the grinding tool of the rubber
head to suck the valve
Grinding the valve seat.
Remove the valve and check the valve,

the width of the contact surface
Standard value: 1.2~1.6mm

Note: If the valve contact surface is rough,

uneven wear or improper contact with the
valve seat, the valve should be replaced.
valve
5-24
Valve duct reamer
Measuring the width of the valve seat

contact surface
If the valve seat is too wide, too narrow or

has a dent, the valve seat should be ground
to the correct degree of sealing.
Contact width
Valve seat milling cutter

Three different angles of milling cutter
5-25
5 发动机
Flat trimming knife Valve correction knife Internal trimming knife
Milling the upper ring of the valve seat with

a 32° milling cutter Width of old valve seat
Finish the valve seat's work surface with a

45° milling cutter to the correct width.
Milling the bottom ring of the valve seat Working face width standard value：1.0mm
with a 60° milling cutter
Apply ink to the valve seat and insert it into

the valve to rotate
Then take out the valve and see if the
contact surface is in good condition.
Width of old valve seat
Note: The situation of contact surface

between the valve and the valve seat will
be a very important factor for the
engine's tightness.
If the valve contact surface is too high, it can

be abolished with a 32° milling cutter to
reduce the contact surface
26
Contact surface too low

If the valve contact surface is too low, use a
60 ° milling cutter to raise the contact
surface.
Finally, the 45° milling cutter is used for
machining and abolishing, and the valve seat
contact surface is machined to the pre-set
width.
After the valve seat is finished, the valve

seat should be coated with abrasive
Then, install the valve and grind the upper
valve with a rubber head for grinding.
After grinding completed, clean all abrasives
remaining on the cylinder head, valve seat
and valve guide
5.5.15 Cylinder head assembly
Note: Before assembling the valve, the oil

shield should be placed on the valve
guide.
After applying oil to the intake and exhaust

valve stems, install them into the valve
guide. Install the valve spring and valve
spring seat.
Note: When installing the valve spring,

the denser end of the spring should be
Contact surface too high made toward the cylinder head.

Then use the valve remover to press down
the valve spring, then insert the valve lock
5-27
5 发动机
clip into the valve spring seat.
Note: To prevent permanent deformation

of the valve spring, do not over compress
the spring , only need to fit the valve lock
clip.
Then tap the end of the valve with a plastic

hammer to make the lock clip firmly into the
ring groove.
5.5.16 Cylinder head installation
Install new gasket and locating pin
Note: Do not allow dust and impurities to

enter the cylinder
Oil shield
Install the cylinder head and insert and
support the timing chain to prevent it from
falling into the box.
Install the cylinder block connecting bolt
2×M6
Torque value: 8~12N·m
Mounting the camshaft on the cylinder
head
Mount the rocker support bracket
Install the Ab bolt fastening nut and
gasket ring
Nut torque：28~30
Note: When installing the camshaft, first
5-28
brake the magneto rotor in a clockwise

direction so that the “T” mark is aligned
with the indicator. At the same
time,ensure that the 2×Φ3 hole
connection line is parallel to the head
cover joint surface, and the Φ6 hole is
perpendicular to the head cover joint
surface. When tightening the cylinder
head, first tighten the AB bolt nut and
then tighten the cylinder connection bolt.
Injecting lubricant
Note: Before installing the camshaft, fill

the oil groove on the cylinder head with
clean engine oil until the cam on the
camshaft can be immersed in the oil..
Ø6 hole 2×Ø3 hole
5.5.17 Cylinder head cover installation
Install a new "O" ring into the groove on the

Dowel pin Sealing gasket cylinder head cover
Install the cylinder head cover and tighten
the 4 reel bolts
Ab Bolt lock nut
5-29
5 发动机
Disc bolt
Cylinder head cover
5.6 Cylinder and piston

5.6.2 Cylinder disassembly…………………………………………………………………5-31
5.6.3 Piston disassembly……………………………………………………………………5-31
5.6.4 Piston installation……………………………………………………………………5-33
5.6.5 Cylinder installation…………………………………………………………………5-34
The camshaft lubricating oil is injected into the cylinder head through a measuring hole in the
engine casing. This measuring holes must not be blocked. Before installing the cylinder,
install new gaskets and locating pins; do not allow dust and impurities to seep into the
5-30
crankcase..
Specifications
item standard（mm） Maintenance limit（mm）

Cylinder inner diameter 62~62.01 62.1
Taper — 0.10
cylinder
Out of roundness — 0.10
Top distortion — 0.10
Piston diameter 61.965~61.975 61.78
Piston pin hole inner diameter 15.002~15.008 15.04
Piston pin and piston pin hole
0.002~0.014 0.02
clearance
Top ring /
Piston ring 0.250~0.350 0.50
Piston, second ring
end gap
piston Oil ring 0.3~0.7 —
ring and Clearance Top ring 0.015~0.050 0.09
piston between
pin Piston ring
Second ring 0.015~0.045 0.09
and piston ring
groove
Clearance between Cylinder and
0.03~0.06 0.10
piston
Piston pin outer diameter 14.994~15.000 14.96
Connect Inner diameter 15.014~15.022 15.064
ing rod
small Clearance between Connecting
0.01~0.034 0.10
end rod end and piston pin
Low or unstable compression: Overheat:
1. Cylinder or piston ring is worn 1. Excessive carbon deposit
2. The cylinder, piston or piston ring is 2, there is knocking or abnormal noise
worn 3, the piston or cylinder is worn
3. The piston ring is not installed
correctly.
4. Scratches or scratches on the piston or
cylinder wall
5.6.2 Cylinder disassembly Cylinder
5-31
5 发动机
Remove the cylinder head (→5.5.5)

Remove the positioning pin and paper pad
Remove the cylinder
Note: When removing the cylinder, the timing

chain must never fall into the crankcase.
Scrap the paper gasket remainings on the cylinder

surface with a scraper. Top
Middle
Note: If the paper gasket is immersed in gasoline, Bottom
it is easy to disassemble. Avoid damage to the
cylinder contact surface during this operation.
Cylinder inspection
Check the cylinder for wear or damage

5.6.3 Piston disassembly
The inner diameter of the cylinder should be
measured in three positions, that is, the top, middle Remove the piston pin retaining
and bottom of the piston stroke, and should be in two ring with pliers
directions at right angles to each other.
Maintenance limit: 62.1mm Note: The retaining ring cannot
Measure the taper and out of roundness be dropped into the crankcase.
Out of roundness: 0.10mm：0.10mm
Press the piston pin out of the
piston and remove the piston
Piston/piston ring inspection
Measuring the gap between the

piston ring and the groove of the
piston ring
Maintenance limit:
First ring: 0.09mm
Second ring: 0.09mm
Remove the piston ring
Note: Do not damage the piston

ring when disassembling.
5-32
Insert each piston ring into the cylinder and

measure the end gap
Maintenance limit:
First ring / second ring：0.5mm
Check the piston and piston ring groove for wear or

cracks.
Measuring piston pin hole inner

diameter
Measure the outer diameter at 10

mm above the bottom end of the
piston skirt
Calculate the gap between the
cylinder and the piston
Thick Gauge
Measure the outer diameter of the
5-33
5 发动机
piston pin
Calculate the gap between the piston and the piston
pin
5.6.4 Piston installation
Piston ring installation
Thoroughly clean the piston ring

groove
Assemble the piston ring
Note: Pistons and piston rings

should be protected during
installation.
damage
When installing the piston ring,
the marked side is facing up
After installation, the piston ring
should be free to rotate
Do not reverse the mounting
position of the top ring and the
second ring.
Separate the piston ring end gap by

120°, do not align the gaps of the
oil rings with each other.
An oil ring consisting of three rings,

the gap between the rings should
match the gap of the spacer
When installing the oil ring, install
the spacer first, then install the side
ring.
20mm
5-34
Piston installation
Top Ring
Install the piston, piston pin and new piston retaining Second Ring
ring. Oil Ring
20mm or bigger
Note: When installing the piston, the side marked Gap
with the “IN” mark should be aligned with the
intake valve.
The end gap of the piston pin retaining ring should be
staggered from the piston incision
Clip Spring
Clip Spring
Clip Spring
Top Ring Note: When assembling after
Second Ring disassembly, be sure to use a new
Oil Ring piston
Pin retaining ring
DoClip
not Spring
let the piston pin retaining
Clip Spring
ring fall into the crankcase.
Piston mark
5.6.5Cylinder installation
Install new paper gasket and

positioning pin
5-35
5 发动机
Apply a layer of oil to the cylinder and piston ring

Install cylinder
Note: When installing, avoid destroying the piston

Can't let the timing chain fall into the crankcase.
Install the timing chain guide plate
Install new paper gasket
Install the positioning pin
Install the cylinder head
Piston pin retaining ring
Clearance of
Retaining ring
Loophole
5.7 Oil pump

5.7.1 Disassembly of the oil pump…………………………………………………………5-35
5.7.2 Oil pump inspection…………………………………………………………………5-36
5.7.3 Oil pump installation…………………………………………………………………5-37
5-36
The installation and maintenance work after removing the right crankcase cover can also be
operated without removing the engine;
Do not allow dust or impurities to enter the engine when the oil pump is removed;
It is not allowed to repair the oil pump. If a certain size reaches the maintenance limit, the
entire oil pump should be replaced.
Technical specifications
Maintenance limit
item standard（mm）
（mm）
clearance between inner
— 0.12
rotor and outer rotor
Oil pump
clearance between outer
— 0.12
rotor and pump body
Axial clearance between
0.05~0.1 0.2
rotor surface and pump body
5.7.1 Disassembly of the oil pump Oil pipe, Spring
M14 NUT
Remove the oil pipe and spring
Remove the magneto motor fastening nut M
Rotor
14 and washer
Remove the magneto rotor
Remove the one-way tightening nut M 22
(left-handed) and washer Unidirectional
Remove the one-way device Washer
Remove the oil pump sprocket cover
fastening bolt 2×M6 Unidirectional
Remove the oil pump sprocket cover Device
Remove the oil pump driven wheel lock nut
M6 bolt
Remove the balance shaft lock nut M16
Sprocket Cover Fastening Oil pump
(left-handed)
bolt driven wheel
Remove the oil pump main and driven
Sprocket cover
wheels
Remove the oil pump lock bolt
Remove the oil pump
5-37
5 发动机
External Rotor
5.7.2 Oil pump inspection
If the radial clearance between the outer

rotor and the pump body is greater than 0.12, Pump
the oil pump should be replaced. body
External Rotor
If the radial clearance between the inner

rotor and the outer rotor is greater than 0.12,
the oil pump should be replaced.
Internal Rotor
If the axial clearance between the rotor

surface and the pump body is greater than
0.2, the oil pump should be replaced.
5.7.3 Oil pump installation
Locking bolt
of oil pump
Install the oil pump in the correct position
(pump mark control, mark hole on the box)
Install the oil pump lock bolt
Install the oil pump main and driven wheels
Install the balance shaft lock nut M16
Oil pump Install the oil pump driven wheel lock nut
M6
Install the oil pump sprocket cover
5-38
Install the oil pump sprocket cover fastening

bolt 2×M6
Install one-way device
Install the one-way fastening nut M 22 and
washer
Installing a magneto rotor
Install the magneto motor fastening nut M
14 and washer
Install oil pipe and spring
5.8 Right crankcase cover and magneto

5.8.1 Disassembly of the right crankcase cover……………………………………………5-38
5.8.2 Magnetic motor disassembly…………………………………………………………5-38
5.8.3 Magnetic motor installation…………………………………………………………5-39
5.8.4 Right crankcase cover installation……………………………………………………5-39
5-39
5 发动机
For the disassembly and installation of the magneto motor described in this section, simply
remove the right crankcase cover, no need to remove engine.
Torque value
Right crankcase cover fastening bolt: 8~12N·m
Magneto rotor bolt：35~40N·m
5.8.1 Disassembly of the right
crankcase cover
Remove the 9×M6 bolt

9×M6 bolt
Remove the right crankcase cover
Right crankcase cover
Oil tube, Spring

5.8.2 Magnetic motor disassembly
Remove the oil pipe and spring M14 bolt

Fix the flywheel rotor
Remove the rotor fastening nut M14 Rotor
Remove the magneto rotor with the rotor
puller
5.8.3 Magnetic motor installation
Install the magneto in reverse order of

disassembly
5-40
Note: The semi-circular button on the

crankcase is aligned with the magneto motor
groove
Tighten the rotor nut to the specified

torque value
Torque value：35~40 N·m
5.8.4Right crankcase cover
installation
First install the stator coil

Stator coil
Then tighten the 9×M6 bolts according to

the specified torque.
9×M6 bolt
9×M6 bolt
5.9 CVT parts
5-41
5 发动机
5.9.1 Disassembly of the left crankcase cover……………………………………………5-40
5.9.2 Disassembly of CVT parts……………………………………………………………5-40
5.9.3Inspect of CVT parts…………………………………………………………………5-41
5.9.4 Install of CVT parts…………………………………………………………………5-42
5.9.5 Left crankcase cover installation……………………………………………………5-42
The removal and detection of the left crankcase cover and CVT components eliminates the
need to remove the engine from the frame and can be disassembled and tested directly on the
vehicle.
5.9.1 Disassembly of the left
crankcase cover
Remove the left crankcase cover tighten bolt

9×M6
Remove the left crankcase cover
Fastening bolt
M12 Nut M12 Nut
5.9.2 Disassembly of CVT parts
Remove the M12 nut and washer

Remove the active drive plate and the driven
friction plate
Remove the drive disc bushing
Active drive disc Driven friction disc
5-42
Driven friction disc

Take out the belt

Take out drive and driven parts
Active disc bushing Belt
5.9.3 Inspect of CVT parts
Belt width less than 17mm should be

replaced
The sliding drive disc has a hole diameter

greater than 27.06mm and should be
replaced.
Sliding drive disc
The outer diameter of the sliding drive disc

sleeve less than 26.94mm, then need to
replace.
Clutch friction disc inner diameter greater Sliding drive disc sleeve
than 130.5 mm should be replaced.
Clutch friction disc
5-43
Clutch friction disk

5 发动机
Clutch friction material thickness less than

2mm, then need to replace.
Clutch
5.9.4 Install of CVT parts
Clutch
Install the drive pulley unit

Install the belt into the clutch
Install the clutch

Active pulley components
Install active drive plate and driven

friction plate
Fasten M12 nut and washer
Note: When tightening the nut, first

tighten the nut at the active drive plate. Clutch
5.9.5 Left crankcase cover
installation
Mounting pin
Install the left crankcase cover (bolt 9×
M6) Active drive disc Driven friction disc
Fastening bolt
5-44

5.10 Crankcase, crankshaft, variable speed drive

5.10.1 Troubleshooting……………………………………………………………………5-44
5.10.2 Decomposition of the crankcase……………………………………………………5-45
5.10.3 Crankshaft inspection………………………………………………………………5-45
5.10.4 Decomposition of transmission components………………………………………5-47
5.10.5 Assembly of transmission parts……………………………………………………5-48
5.10.6 Assembly of crankshaft components………………………………………………5-48
This section describes the disassembly and assembly of the transmission components and the
crankshaft. When performing the above work, the crankcase should be separated first; the
disassembly of other components of the engine should be performed before the crankcase is
disengaged.
Work before crankcase separation
Cylinder head removal

Cylinder and piston disassembly
Disassembly of the right crankcase cover, magneto, and oil pump
Disassembly of the left crankcase cover and CVT components
Specifications
Maintenance limit
item standard（mm）
（mm）
inner diameter 12.00~12.018 12.05

Gear shift
fork
Claw thickness 4.93~5.00 4.50
Gear shift
outer diameter 11.966~11.984 11.950
fork shaft
Connecting rod small
15.014~15.022 15.06
head inner diameter
Clearance
Crankshaft
of
Radial 0.004~0.008 0.05
Connecting
rod side
5-45
5 发动机
Difficulty gear shifting Crankshaft has noise
1. gear shift fork bent 1, the connecting rod big end bearing
2, gear shift fork shaft bent wear
2, connecting rod bent
Gear shift abnormal
1. The gear shifting ratchet claws are Gear shifting gear is noisy
worn 1. Gear shifting gears are worn
2. The gear shift fork is bent or damaged. 2, spline bearing wear
3, gear shift fork shaft bending
5-46
5.10.2Decomposition of the
crankcase
Place the engine on the workbench

Remove the right crankcase box bolt 8×M6
Remove the left crankcase box bolt M6
Turn the engine over so that the right

crankcase is above
Remove the right crankcase and separate the
left crankcase from the right crankcase
Remove the gasket and locating pin
Remove the crankshaft and balance shaft
Remove the transmission mechanism
Remove the shifting mechanism
Blance shaft
Transmission gear Shift gear Crank shaft

Locatin
g pin
5.10.3 Crankshaft inspection
Place the crankshaft on the V-shaped iron

Measuring the curvature of the crankshaft
with a dial indicator
The actual curvature of the crankshaft is 1/2
of the total reading (TIR)
5-47
5 发动机
Measuring radial clearance of two points in

the X and Y directions of the large
connecting rod
Measuring the big head gap of the

connecting rod with the feeler gauge
Turn the crankshaft bearing by hand and

check its jumping in radial and axial. If the
engine is noisy and the radial or axial
jumping direction is too large, it should be
replaced. Free stroke
Free stroke
Timing sprocket disassemblely/ installation
Disassemble the timing sprocket on the

crankshaft and check if sprocket teeth
wearing or damage.
Install the sprocket on the crankshaft, the
center of the gear should be aligned with the Axial Radial
keyway on the crankshaft
5-48
5.10.4 Decomposition of
transmission components
Pull out the fork shaft and take out the fork
Take out the shift drum and shift shaft
Take out the reverse intermediate shaft and
reverse drive shaft assembly
Shift Speed Revers Reverse

Shaft shift middle transmission
drum axle shaft
Shift fork, shift fork shaft, shift drum
inspection
Check if each shift fork is wearing, bending

or any other malfunction
Measuring the shift fork inner diameter and
the thickness of the shift claw
Inner diameter maintenance limit: 12.05mm
Thickness maintenance limit: 4.5mm
Check if the shift fork shaft is wearing or

bending
Measuring outer diameter
Check if the shifting fan sector teeth are

abnormally damaged
Counter shaft
Check if each tooth is abnormally worn
teeth
Teeth of variable speed drum fan
Sector
Teeth of reverse teeth
intermediate of shift
Teeth of reverse
shaft shaft
transmission shaft
teeth
5-49
teeth
5 发动机
5.10.5 Assembly of transmission
parts
Reverse
Install the components in the correct middle
position, as shown in the picture: Variable speed drum
Axle
Shift shaft Reverse
Transmission
Note: Before assembly, each part should Axle
be coated with engine oil.
Check if the shift gear can rotate freely
and without jamming.
Care should be taken to align the
marking teeth when assembling the
shifting drum and shifting shaft.
Alignment of labeled teeth
Packing box pad

5.10.6 Crankshaft assembly
Lay the left crankcase flat on the workbench

Place the timing chain in the position Fit the positioning pin
showed in picture. Install
Timing the left crankcase
chain
Load the balance shaft into the left Fasten the bolts at the left crankcase
crankcase Fasten the box bolt at the right crankcase
Coupling bolt torque value:
Crank8~12N·m
part
Note: After the crankshaft is assembled
correctly, the timing chain should be able
to pull freely without jamming.
Balance shaft
5-50
Fit the positioning pin

Install the left crankcase
Fasten the bolts at the left crankcase
Fasten the box bolt at the right crankcase
Locating Pin Coupling bolt torque value: 8~12N·m
Closure bolt
Left crankcase
Closure bolt
5-51
5 发动机
5.11 Fault judgment

5.11.1 Engine can't start or start difficult…………………………………………………5-50
5.11.2 Engine power is Insufficient……………………………………………………5-51
5.11.3 Poor performance at low engine speed or idle speed………………………………5-52
5.11.4 Engine performance is poor at high speeds…………………………………………5-53
5.11.5 The engine has abnormal noise……………………………………………………5-54
possible reason
5.11.1 Engine can't start or start hard 1. No fuel in the fuel tank
2, the oil switch is blocked
Check direction 3, tubing blockage
4, carburetor float needle
1、Check if the fuel reaches the carburetor → does not card jam
enter the carburetor → has entered the carburetor
possible reason
1. The spark plug is damaged
or not cleaned
2, the magnetic motor failure
3, ignition switch failure
2、Remove the spark plug and check the spark → the spark 4, sensor failure
is weak or completely no fire → the spark is normal 5, igniter failure
6, ignition coil failure
7, high voltage cable failure
8, the power circuit has a
short circuit or open circuit
possible reason
1、Check cylinder pressure → pressure is too low → 1. The valve clearance is too
pressure is normal small or has no gap
2, the valve guide Xuan bent
3. The cylinder seat and the
valve are not well matched.
4, cylinder and piston ring
wear
5, the cylinder head gasket is
2、Restart the engine → the engine can ignite but still not sealed well
can't start → the engine does not ignite 6, the assembly is not in
place
7, the timing of the valve is
not correct
possible reason
5-52
1. Throttle opening is too large carburetor is not blocked

2. The carburetor plunger fine adjustment screw is
improperly adjusted.
3, the intake pipe leaks
4, the ignition timing is not correct
5, remove the spark plug → spark plug wet → spark plug
drying
6. Close the choke and restart the engine.
possible reason
1, carburetor rich
2,The carburetor choke is not open
3, the throttle is too large
5.11.2 Engine power is Insufficient

possible reason
Check direction 1, carburetor rich
2. The carburetor choke is
1. Gradually increase engine speed → no change in engine not open
speed → normal engine speed increase 3, the throttle is too large
possible reason
1, the fuel system is not well
supplied
2, carburetor choke closed
2. Check the ignition timing (using the ignition timing light) 3, air filter blockage
→ the ignition switch is incorrect → the ignition timing is 4, carburetor cover air hole
correct. blockage
5, silencer blockage
possible reason
3. Check the valve clearance → the valve clearance is 1. CDI igniter is damaged
incorrect → the valve clearance is correct. 2, the magneto is faulty
3, pulse generator failure
possible reason
4. Check cylinder pressure → cylinder pressure is too low 1. Improper adjustment of
→ cylinder pressure is normal valve clearance
2, valve seat wear
possible reason
1, the valve clearance is too
small
5. Check the carburetor → carburetor blockage → 2, the valve is bent or stuck
6-53
1
5 发动机
3, valve seat wear

4, cylinder and piston ring wear 1、Check direction
5, cylinder gasket damage
6, the timing of the valve is not correct 1. Check ignition timing and
7, the spark plug is not assembled in place valve clearance → incorrect →
correct
possible reason
1, the fuel is not clean
2. The carburetor is not cleaned regularly
2.Check if the carburetor

connection has leakage → there
is air leakage → no air leakage
6. Check the spark plug → the spark plug has too much
carbon or the color is wrong → the spark plug is normal possible reason
1, did not do regular maintenance
work
2, the spark plug heat value is
7. Remove the oil dipstick and check the oil volume → the wrong
oil quantity is incorrect → the oil quantity is normal. 3, the spark plug electrode gap is
too small
8. Remove the valve cover and check the lubrication of the possible reason
valve → the valve lubrication is not normal → the valve 1, the oil surface is too high
lubrication is normal 2, the oil surface is too low
3, the oil is not clean
possible reason
9 Check if the engine is overheated → the engine is 1. Oil passage is block
overheated → the engine is not hot 2. The oil pump is not working
properly.
possible reason
1. Excessive carbon deposit in the
10. During high-speed driving → the engine emits a combustion chamber
knocking sound → the engine has no knocking sound 2. The fuel used does not meet
the specifications.
3, the clutch slips
4, the mixture is too rich
5, too much oil
5.11.3 Poor performance at low engine speed possible reason

1, piston and cylinder wear
and idle speed
5-54
2. Excessive carbon deposit in the combustion chamber

3. The fuel used does not meet the specifications.
4, the ignition timing is too much ahead
2. Disassemble the carburetor

fuel pipe → the fuel flow is
restricted → the fuel can
flow freely
possible reason
1, CDI failure
3, sensor failure
4, the valve clearance is too small
3. Check the carburetor →
possible reason carburetor is blocked →
1. Carburetor seal ring deformation carburetor is not blocked
2, the carburetor connection is loose
3, the seal ring rupture
4, check the timing of the

valve → not correct →
Check spark plug fire condition → spark is weak or intermittent correct
fire jump → spark is normal
possible reason
1, spark plug damage
4, CDI failure
5, the transmitter failure
6, switch failure
7, spark plug cap failure
5.11.4 Poor performance at high engine speed 8, the power circuit has a
wrong connection or short
Check direction circuit
1. Check ignition timing and valve clearance → incorrect

→ correct
6-55
1
5 发动机
5.11.5The engine has
possible reason
abnormal noise
1. Magneto motor failure Check direction
2, CDI failure
3, sensor failure 1. The valve makes an
4, improper valve clearance abnormal sound
1. The fuel in the fuel tank has been used up.

2, the fuel tank lock cover air hole is blocked
3, the fuel tank to the carburetor oil circuit is blocked 2, piston and cylinder stroke
4, the oil switch is blocked
5, gasoline filter is blocked
possible reason 3, bearing abnormal sound

1, the float needle is blocked
2, the float oil level is too low
3, carburetor volume hole is blocked
4, the float stuck
4, the cam chain is different
possible reason
1. Timing chain and timing sprocket are not installed
correctly. 5. Transmission gear and
2, gear wear is serious driven gear are different
possible reason
5, check the spark plug high-speed flashover situation → 1. Magneto motor failure
jump fire is not normal → jump fire is normal 2, CDI failure
3, sensor failure
4, ignition switch failure
6, spark plug cap failure
7, spark plug failure
8, the power circuit has a
5-56
short circuit 4, improper adjustment of the

chain regulator
possible reason
1. The machining accuracy of
the gear is not good
possible reason
1, the valve clearance is too large
2, valve worn out
possible reason
1, piston and cylinder worn out
2, piston pin and small end connecting rod worn out
3, crank connecting rod head worn out
possible reason
1. Crank connection bearing is damaged
2, camshaft bearing worn out
possible reason
1, the chain is elongated
2, timing sprocket wheel tooth worn out
3, chain adjustment plate or guide plate worn out
6-57
1
6 车辆底盘
6 Vehicle chassis
Maintenance information………………………………………………………… 6-2
6.1 Troubleshooting…………………………………………………………………6-3
6.2 Front wheel……………………………………………………………………6-3
6.3 Braking System…………………………………………………………………6-4
6.4 Front suspension system………………………………………………………6-6
6.5 steering system…………………………………………………………………6-8
6.6 Rear suspension system………………………………………………………6-12
6.7 Rear drive shaft assembly……………………………………………………6-12
6-2
Attention
• When carrying out maintenance work on the front wheel and suspension system,
the frame must be securely supported before it can be used.
• Inspection, inspection and inspection of lights, instruments and switches are carried
out according to the corresponding chapters.
• Do not use excessive force on the wheels. Be careful not to damage the wheel
• When removing tires from the rim, special tire and rim protectors must be used to
avoid damage to the rim
Maintenance standard
item standard Use limit

Axial runout 0.8mm 2.0mm
Rim
Radial runout 0.8mm 2.0mm
Residual trench — 3mm
wheel
Air pressure 35kPa(0.35kgf/cm2) —
Front brake Brake handle clearance 0mm —
Tightening torque
item size torque
Steering lock nut GB9457 M10 × 1.25 33~45N·m
Front brake disc bolt M8 × 20 × 1.25 22~30N·m
Front brake caliper body bolt GB5789 M8 × 16 30~36N·m
Rim shaft slotted nut GB9457-1988 M14 ×1.5 × H18 209～278N·m
Front shock absorber bolt GB5789 M10 ×1.25 × 45 Half thread 45～59N·m
Rim mounting nut GB6187-86 M10 × 1.25 45~59N·m
Lower rocker bolt GB5789 M10 × 1.25 × 80 45~59N·m
tool
inner hexagon m6 Assembly tool shaft
Open ratchet wrench s8 Pneumatic wrench s12
Open ratchet wrench s10-s12 Pneumatic wrench s14
Open ratchet wrench s14 Socket wrench m12
Open ratchet wrench s17-s19 Socket wrench m14
6-3
6 车辆底盘

Phillips screwdriver Needle-nose pliers
Flat mouth screwdriver External circlip pliers
hammer
6.1 Troubleshooting
Steering is too heavy 1, poor wheel bearing
2. Improper installation of the front
1. The upper bolt of the direction wheels
column is too tight 3, brake tubing, cable clamp
2. Steering bearing damage and wear Fifth, the front suspension is too soft
3, the inner and outer races of the 1. The front shock absorber is
bearing are damaged, worn, and stepped weakened
4, the direction column deformation 2, the tire pressure is too low
5, low tire pressure Sixth, the front suspension is too hard
6, tire worn out 1. The front shock absorber is
Second, the handle bar is shaking damaged.
1. Steering bearing damage and poor 2, the tire pressure is too high
fastening Seven, the front shock absorber
2, left and right shock absorbers are abnormal sound
not supported 1. The front shock absorber is
3, tire skew defective
4, frame deformation 2. Loose parts of the shock absorber
5, tire eccentric worn out are loose
6, wheel bearing shaking Eight, poor braking effect
Third, the front wheel is jumping 1, poor brake adjustment
1, rim deformation 2, the surface of the brake disc is
2, poor wheel bearing defaced
3, bad tires 3, brake pad wear
4, improper wheel balance
5, poor fastening around the wheel
axle
Fourth, the wheel is not turning well
6.2 Front wheel 1
Disassembly that no force is applied to the front wheel

Remove the four nuts that are attached to the
front wheel bracket 1
Remove the front wheel 2
Raise the front wheel with a tool to ensure
6-4
6.3 Brake system

Front brake caliper disassembly
Remove the front wheel
Remove the 2 bolts mounted on the steering
knuckle 6
Remove the brake caliper 7
examination
Observe the brake1caliper for cracks, oil
Wheel inspection
Check if the rim 1 has damage, deformation,
and scratches. Replace if there is any
abnormality. Slowly turn the wheel and
measure the runout of rim 1 with a dial
gauge
Use limit: axial: 2.0mm
Radial: 2.0mm
Rim installation
Press the rim 2 into the tire on a special 2
machine
3
Front wheel mounting bracket removal
Remove the front caliper body 3
Take out the cotter pin 4
Remove the rim shaft mounting nut 5
Brake disc and mounting bracket are
4
removed together
4
Remove the front wheel mounting bracket
Installation
Installation in reverse order of disassembly 5
Wheel rim mounting nut torque: 209N•m～ 4
278N•m
Brake disc mounting bolt torque: 30N•m～
36N•m (threaded fixative) leaks at each fastening point, and replace
Note: The rear wheel is disassembled and installation
installed similar to the front wheel, please Brake caliper fixing bolt 2 Torque: 38N•
refer to the front wheel. m～51N•m (Threaded fixing agent）
7
6- 5
6 车辆底盘
vehicle body when the brake pump assembly

is not replaced.
Installation
Installation in reverse order of disassembly
Note: Do not use the brake hose to suspend

the brake pump
Fearing that the front brake hand brake
pump is dumped will2 cause air to enter the
hydraulic system, so keep it in the direction
Brake pad removal
Loosen a fastening bolt
Rotating brake caliper 1
Remove the brake pad 2
examination
The thickness of the brake pad friction layer
2 is measured. When the thickness of the 1
brake pad friction layer 2 is less than or
equal to 1 mm, the two brake pads are
simultaneously replaced with a new one.
Installation
Brake disc removal

Remove the brake caliper
Remove the brake disc 3 and the front wheel 3
bracket 4 from the vehicle together
examination
Front brake disc thickness: less than 3.0mm,
replace the new brake disc 4
Installation
Install the brake disc
Brake disc fixing bolt torque: 22N•m～30N
•m of the mounting position while fixing it to
the steering handle.
Disassembly of front brake hand brake The direction of the oil pipe on the car body,
pump according to the first chapter cable, wire
Remove the bolt 5 type routing, must ensure the smooth flow of
When the front brake hand brake pump 6 is the brake oil circuit.
disengaged, the front brake hand brake When the brake system assembly is installed,
pump does not need to be removed from the the braking force must be checked.
6- 6
6.4 Front suspension system

5 Disassembly of the right front suspension
combination
Note: When repairing the suspension system,
the left and right suspension systems cannot
be removed at the same time, otherwise the
car body will fall down without support.
Brake tee joint disassembly
Remove the bolt 1
Will brake the tee joint 2 separate the car
body
Installation 1
Note: The direction of the oil pipe on the car
body, according to the first chapter cable,
wire type wiring diagram, must ensure the
smooth brake system of the brake oil circuit, 2
when the assembly is installed, the braking
force must be checked
3
Rear brake caliper body removal

Remove the bolt 3, parking brake cable 4
Remove the rear brake caliper 5
installation
Note: The direction of the oil pipe on the car
body, according to the first chapter cable,
wire type wiring diagram, must ensure that 4
the brake circuit of the brake circuit is
installed, the brake force must be checked, if
the front and rear can not be linked control
Brake system, check whether the joint is 5
connected. Check whether the brake fluid in Park the car body at the level on the ground
the brake oil cup is between the upper and and secure the front of the vehicle with a
lower limit marks. If necessary, add the jack.
brake fluid recommended by KAYO to the Remove the front assembly board
upper and lower limit marks. Check that the Remove the front wheel
brake switch and brake light are working Remove the brake caliper
properly. Remove the front hub bracket
6- 7
6 车辆底盘
Remove the bolts on the front and rear lower suspension

rocker arms of the right front shock
absorber.
Remove the front shock absorber 7
6
1
Remove the bolts on the frame and the nuts

that fasten the bolts on the right front upper
7
rocker arm 1
Remove the right front upper rocker ball pin
and install the split pin and nut on the right
knuckle 2
Remove the right front upper rocker arm 3 2 3
Remove the split pin and lock screw on the
steering rod ball pin 4 5
Remove the bolts and nuts that are attached

to the frame by the right front lower rocker
arm. 5
Remove the right front lower rocker ball pin
locking bolt 6
Remove the right front lower rocker 7
Pull the steering knuckle out of the drive
shaft. The car's suspension system is
available in a variety of configurations to
suit different customer groups. The above 6 7
describes the suspension system of the basic
configuration. The maintenance methods of
the suspension system of other
configurations are similar. You can refer to
the above method for maintenance.
Installation
The disassembly, installation and inspection

method of the left front suspension
combination is combined with the right front
6- 8
Disassembly and assembly of the right front

rocker arm
Remove the right front shock absorber
Remove the bolts on the frame and the nuts
that fasten the bolts on the right front upper
rocker arm 1
Remove the bolts that attach the right front
lower rocker arm to the frame and the nuts
that tighten the bolts. 5
Before removing the shock absorber, first
remove the wheel, brake caliper and rim
bracket
Before removing the bolts, first remove the
steering rod
Pull the knuckle out of the front constant
drive shaft before removing the right front
rocker assembly
8
Remove the right front rocker arm
combination
Check the upper and lower rocker arms
Remove the right front upper rocker welding
combination 3
Remove the upper ball combination 8

2
Check whether the grease in the ball pin has
deteriorated (grease type: No. 2 lithium
grease GB7324-87). Whether the dust cover
on the ball pin is broken or aged, if there is
any problem, replace the new ball pin.
Remove the buffer sleeve combination in the
right front upper rocker welding
combination to check whether the buffer
sleeve combination is damaged or
deteriorated, and if necessary, replace it with
a new one.
6- 9
1
6 车辆底盘
Installation
disassembly.
Remove the right front lower rocker welding

combination
Remove the lower ball combination 1
Check if the lower pin combination 1 can be
2
flexibly rotated in all directions and the
clearance in the upper ball pin, if it is not
flexible or the clearance is too large; check
whether the grease in the ball pin is
deteriorated (fabric type: No. 2 lithium
grease GB7324 - 87), if the dust cover on
the ball pin is broken or aged, if the above
problem occurs, the new ball pin should be
replaced.
Remove the buffer sleeve combination in the
right front lower rocker welding
combination
Check the buffer sleeve combination 2 for
damage, aging, and replace with new if
necessary.
1
installation
Press the ball pin into the rocker arm
combination with a special tool
Note: The upper and lower rocker arms

should not be shaken after installation. If
there is shaking, replace the new buffer
sleeve combination.
Check the right knuckle

Remove the right knuckle
Remove the hub bearing with a special tool
Check if the hub bearing is damaged, if the
rotation is flexible, if the clearance is too
large, and if there is a defect, replace it with
a new one.
6-10
Release connector
Remove the left handle switch
multi-function plug 8
Installation
The left and right hand switch assemblies
are reversed in reverse order
6.5 steering system 1
Direction 2
Dash cover removal

Remove the instrument cover 1 , instrument 3
panel 2 ,
Installation
Handle removal 4
Disassembly of the right hand switch
assembly
Remove the screw 4
Remove the bolt 5
Remove the front hand brake pump
Remove the right hand switch assembly
5
Disassembly of the left hand switch

assembly
Remove the screw 6
Remove the bolt 7
Remove the rear hand brake pump
Remove the left handle switch assembly
6-11
6 车辆底盘
Throttle cable
6 Disassembly
Remove the screw 4
Remove the right hand
Remove the throttle cable connector 5
Unscrew the throttle seat connector 6
Remove the throttle cable
Installation
Directional removal of the tube

Remove the meter cover
Remove the left and right handles
Separate the hydraulic brake handbrake
pump from the direction handle
Remove the bolt 1
Remove the upper pressing block 3
Remove the direction to remove the tube 2
Installation 1
Directional mounting bolts for aluminum
cover: M8 × 35
Torque: 30N•m～36N•m
(3.0kgf•m～3.6kgf•m) Note: The main 2
cable assembly, throttle cable, brake oil pipe
and cable connecting wire should be
arranged correctly according to the
picture.
6-12
Remove the fixing bolts 3

Remove the clamp plate 4
Remove the clamp 5
Remove the split pin 6

4 Remove the lock nut 7
The steering shaft assembly can be removed
6 by lifting the steering shaft upwards
Installation
5
Note: When installing the split pin, replace
the new split pin; after the installation is
completed, check the steering flexibility and
the left and right steering angles are the
same; cable and cable type cable according
to the first chapter cable, cable type cable;
When turning the rocker arm, be sure to
place the steering rocker arm in the center
and then assemble the steering shaft. When
assembling the steering shaft, be sure to
assemble it patiently. Make sure that the
right and left steering angles are the same,
steering system
Steering shaft assembly
Disassembly
1
Remove the front assembly board
Remove the direction to remove the tube
Remove the rear brake parking handle
combination 2
Remove the hydraulic brake hand brake
pump
Remove the tube and the left and right
handles
Loosen the lock nut on the steering rod 1
( left and right)
3
Remove the steering lever 2
Remove the steering rocker (1 set for left

and right)
6-13
6 车辆底盘
Remove the bolts on which the rear shock

absorber is mounted on the car body and on
the flat fork assembly 1
Remove the rear shock absorber 2
5 examination
Check the rear shockremoved and adjust the
adjustment cam 3 to the appropriate position
4
installation
6.7 Rear drive shaft assembly
then lock the parts.

ear drive shaft assembly
disassembly
Before removing the rear drive shaft, the

6 vehicle body should be suspended,
otherwise the car body will fall down due to
the lack of support at the rear of the vehicle.
Park the car body at the level on the ground,
and use the jack to stabilize the rear support
of the vehicle and start the operation.
Remove the rear assembly board
Remove the rear wheel
7
6.6 Rear suspension system
Rear shock absorber removal
When repairing the suspension system, the

vehicle body should be suspended first, and
the system should be suspended after
disassembly, otherwise the car body will fall
down due to lack of support.
Park the car body at the level on the ground
and secure the rear support of the vehicle
with a jack
Remove the rear assembly board
Remove the rear wheel
Remove the brake caliper
6-14
1
Remove the drive chain 4
Remove the rear brake caliper
Remove the rear shock absorber
Remove the flat fork assembly and the
frame connecting bolts and nuts
Remove the rear drive shaft assembly
2 3
4
Examination
The rear view of the rear drive shaft assembly of the vehicle is as follows
6-15
6 车辆底盘
quanti quanti
no item no item
ty ty
1 Rear hub 2 9 Flat fork guide sleeve1
2 Big nut 1 10 Rear sprocket seat 1
3 Rear disc brake disc 1 11 Screw（M8×20） 4
4 transmission shaft 1 12 Chain wheel 1
Fastening bolt
5 4 13 Plastic supporter 1
（M12×30×1.25）
6 screw 4 14 Back bridge 1
7 Steel bushing 2 15 ball 1
8 Flat fork assembly 1
Inspection after disassembly of rear drive shaft
 Check if the rear hub is damaged. If it is damaged, replace it with new ones.
 Check the thickness of the disc brake disc. If the thickness of the disc brake is ≤
3mm, replace the disc brake disc with a new one.
 Check if the drive shaft is bent or damaged, if any, replace it with a new one.
 Check the flat fork assembly. If it is damaged, replace it with a new one.
 Check the rear sprocket. If the gear teeth are damaged, replace the new sprocket.
 Check if the remaining parts are damaged. If there is any damage, replace the new
ones.
installation
In reverse order when the rear drive shaft is disassembled
Note: When installing the bushing, apply a lithium grease containing molybdenum disulfide
to both ends of the flat fork shaft.
16
7 Signal and lighting system

Maintenance instructions……………………………………………………………7-1
7.1 Fault judgmen…………………………………………………………………7-2
7.2 Headlight inspection……………………………………………………………7-2
6-17
7 信号及照明系统
7.3 change the bulb…………………………………………………………………7-3

7.4 Ignition switch lock……………………………………………………………7-5
7.5 Hand switch……………………………………………………………………7-6
7.6 Brake light switch………………………………………………………………7-6
7.7 Electric horn……………………………………………………………………7-7
7.8 Meter……………………………………………………………………………7-7
7.9 Fuel sensor……………………………………………………………………7-8
When the inspection work is carried out, the whole vehicle can be energized; when
disassembling and installing the work, the whole vehicle should be powered off first,
and the hands should be dry.
Various specifications
quanti
item size note
ty
Front left turn White cover/ yellow light Light bulb can be
1
signal E4-6R-0162294 changed
Front right turn White cover/ yellow light Light bulb can be
1
signal E4-6R-0162294 changed
JUTELCA5 E4-113R-0125787 Light bulb can be
Left headlight 1
E4-7R-0225787 changed
Right JUTELCA5 E4-113R-0125787 Light bulb can be
1
headlight E4-7R-0225787 changed
LED/Red with
Rear tail light 2 Replace only
plug-inE4-7R-028580
Rear left and
LED/yellow with
right turn 2 Replace only
plug-inE4-6R-0161626
signal
Instrument, 4 pieces of magnetic sensor /
1
light for fault magnet
Electric horn 12V-1.5A EEC II-E9-00.6287 1
7.1 Fault judgment
First, the left headlights are not bright 2, the connector is not well contacted
1, the bulb is damaged 3, the handlebar switch is damaged
7-2
Second, the right headlights are not Six, the rear left turn signal is not
bright bright
1, the bulb is damaged 1, the bulb is damaged
2, the connector is not well contacted 2, the connector is not well contacted
3, the handlebar switch is damaged 3, the handlebar switch is damaged
Third, the front left turn signal is not Seven, the rear right turn signal is not
bright bright
1, the bulb is damaged 1, the bulb is damaged
2, the connector is not well contacted 2, the connector is not well contacted
3, the handlebar switch is damaged 3, the handlebar switch is damaged
Fourth, front right turn signal Eight, the electric horn is not loud or
1, the bulb is damaged too light
2, the connector is not well contacted 1, the speaker is damaged
3, the handlebar switch is damaged 2, the connector is not well contacted
Five, the rear tail light is not bright Damaged handlebar switch
1, the bulb is damaged
2, the connector is not well contacted
3, the handlebar switch is damaged
7.2 Headlight inspection
Turn the ignition switch to ON and turn

the light switch to lighting shift, check if
the headlights are litght or not
- Light up: Normal

- does not light up:
The main cable is broken or shorted
Fuse off
Switch damage
7.3 Lamp replacement
bulb damage
Headlight bulb
If the headlamp bulb is damaged, Note
replace the bulb The headlamp bulb has a large power,
and the temperature is high when the
lamp is turned on. If the light is touched
immediately after the lamp is turned off,
it will be burnt. Must wait for the bulb to
3
cool before working
Remove the front assembly plate 1 1

Unpacking the headlight combination 2
2
Disconnect the headlamp connector 3
Remove the rear cover and headlight

connector and remove the headlamp
bulb and replace it.
note 3
Always wear clean gloves when
replacing the lamp. When oil is attached
to the glass surface, the bulb may be
broken and must be wiped clean with
alcohol or banana water. When replacing
the headlamp bulb, be aware that the
two tabs on the bulb are aligned with the
two locating holes on the socket. Lamp
specifications: 12V-35W 4
installation
After replacing the lamp, adjust the
optical axis of the high beam by
adjusting the screw 4; adjust the optical
axis of the low beam by adjusting the
screw 5. 5
Replace the taillights
Since the taillight bulb is a combination

of LED light-emitting diodes, the bulb
cannot be replaced separately. If it is
7-4
damaged, only the entire taillight can be

replaced.
Disassemble the rear taillight socket

Remove 2 nuts
Take down and replace the taillights 6
installation
Front turn signal bulb

note
When the light is turned on, the
temperature is very high. If the light is
touched immediately after turning off
the light, it will be burnt. Must wait for
the bulb to cool before working
Disconnect the front turn signal

connector 2
1
Remove the nut 3 (1 left and 1 right)
Remove front turn signal 4
Remove the front cover, remove the

front turn signal bulb, and replace
note
2
Always wear clean gloves when
replacing the lamp. When oil is attached
to the glass surface, the bulb may be
broken and must be wiped clean with
alcohol or banana water. When replacing
the headlamp bulb, be aware that the
two tabs on the bulb are aligned with the
two locating holes on the socket. Lamp
specifications: 12V-10W
3
installation
Rear turn signal
7-5
The rear turn signal is a one-piece

structure. If the turn signal is damaged,
only the entire rear turn signal 5
5
combination can be replaced.
Disassemble the rear taillight socket

Remove 2 nuts
Take down and replace the taillights
installation
7.4 Ignition switch lock
Disassembly
Remove the front panel
Disconnect the ignition switch lock

connector 2
Loosen the nut and remove the ignition

1
switch lock 3
an examination
Check the continuity of the switch lock
connector terminals as shown in the 2
table below.
The pattern is normal.
Ignition switch wiring diagram
Black/White
Black Green
Red
Install 3
7-6
7.5 Hand switch

Remove the front panel
Disconnect the connection of the left
hand switch connector 1
Check whether the terminals of each
steering switch connector are turned on
according to the following tables.
The pattern is normal.
Lighting switch 2 wiring diagram
Black Brown
Blue White 1
Stop switch / Electric starter switch 4

wiring diagram Yellow/Red
Black/White
Green
Green 2
Steering switch 5 wiring diagram
Orange
3
Grey Light blue
3：Stop switch
4: electric start switch
Electric horn switch 6 wiring diagram

Purple Green
7.6 Brake light switch

5
Check if the terminals are connected
It is normal to turn on and release the
brake lever when holding the brake lever.
If there is any abnormality in the above
check, replace the brake light switch. 6
7-7
7.7 Electric horn
Disassembly
Remove the front assembly board
Remove the electric horn connector
Remove the nut
Remove the electric horn 1
Examination
When the fully charged 12V battery is
connected, confirm that the electric horn
is ringing.
If there is any abnormality in the above
inspection, replace the electric horn.
Installation
1
7.8 Meter
Start the car body, drive slowly, and
confirm that the instrument display is
normal. If there is any abnormality in
the above check, replace the instrument.
2
Disassembly
Remove the instrument mounting screw
2
Disconnect the instrument cable plug

connector
Remove the instrument fastening nut 3

Remove the dashboard
installation
In the reverse order of disassembly.
note
The main cable and cable type should be
cable, tube,
Cable type wiring diagram is correctly
assembled
3
7-8
7.9 Fuel sensor 1

Disassembly
Remove the fuel sensor fastening screws
1 and remove the fuel sensor from the
fuel tank 2
Disconnect the fuel sensor connector
an examination
Connect fuel sensor connector
Ignition switch is set to ON
Shake the float of the fuel sensor by
hand to confirm the position of the float,
and the scale on the fuel gauge is
consistent.
If it is inconsistent, check if the main
cable is disconnected or shorted. If there
is no abnormality, check the fuel sensor
and the fuel gauge itself. 2
Remove the fuel sensor connector 3
Connect the multimeter to the fuel

sensor connector terminals. Shake the order of disassembly.
fuel sensor float by hand and measure
the resistance of each position of the
float.
Replace the fuel sensor if there is any

abnormality in the above inspection
Installation
Put the fuel sensor into the mounting
hole of the fuel tank, and install it in 3
place. No oil leakage is allowed.
Connect the fuel sensor connector.
Check fuel gauge

Turn on the power and check if the fuel
gauge is working properly.
After confirming that the fuel gauge
indication is normal, install the body
plastic parts and seat cushions in reverse
7-9
附录
Appendix
10

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The contents of this manual are subject

Unit conversion table

Item Unit conversion

Please read the following explanation carefully, which emphasizes the

Danger: Be alert to high risk

1.1 Work precautions

Disassembly and assembly precautions

1.2 Vehicle identification number

1.3 Main parameter list

1.4 Maintenance parameter list

Item Standard limited

Intake system ( 05-Engine section for details)

Wheel（front and rear are the same）

Item Standard limited

Residual trench － 3mm

Item Standard limited

Battery / charging device / trigger coil

Spark plug Spark plug gap 0.6~0.7mm

Pulse generator 20kV~30kV

Starting relay coil resistance 3.5 Ω

Light / instrument / switch

Valve + cylinder head ( section 05 - Engine)

Cylinder + Piston + Piston Ring + Crank Link (section 05 - Engine )

Clutch + transmission（ section 05 - Engine）

1.5 Fastener tightening torque

13 Tow ball fixing plate mounting screw GB70-85 M10×1.5×30 4 45~59

14 Rear hub mounting slotted nut GB9457 M16×1.5 2 199~311

15 Steering column mounting slotted nut GB9457 M12×1.25 1 110~130

16 Steering column clamp mounting bolt GB5787 M8×60 2 22~30

17 Fuel tank front mounting bolt GB5789 M6×25 2 9~12

18 Fuel tank rear mounting bolt GB5789 M6×30 2 9~12

19 Horn mounting bolt GB5787 M6×16 1 9~12

20 Negative pressure switch bolt GB5787 M6×16 1 9~12

21 Engine mounting bolt GB5787 M10×1.25×160 1 45~59

22 Sprocket seat mounting screws GB70-85 M8×20 4 38~51

23 Plastic base mounting screw GB70-85 M6×45 4 13~16

24 Crosshead self-tapping screws GB845-85 ST4.2 — —

25 Crosshead screw GB828-88 M5×16 2 —

26 Crosshead flat screw TM6 — —

27 Rim mounting nut GB6187-86 M10×1.25 16 45~59

Tightening torque at the specified location - engine section ( section 05-Engine )

Engine repair tool (section 05-Engine)

Engine-specific tools (section 05-Engine)

1.6 Lubricating grease, sealant

location note Kind of grease

Cables, bearings, and manipulating lubrication parts

Engine running materials and installation accessorie s（ section 05-Engine）

1.7 Cable, hose, cable wiring diagram

For specific disassembly,check Chapter 2 Body Covers.

6、Voltage regulator rectifier 7, charging connector 8, relay

2 Vehicle Body Covers

2.1 Maintenance information

2.2 Mounting torque

2.3 Disassembly of seat cushion and front/

2.3.3 Rear shelf

2.4 Disassembly of front panel,

instrument panel, gear shift