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2. MAINTENANCE INFORMATIONCYLINDER COPMRESSION PRESSUREWarn up engine and then turnoff the engine.Remove the luggage box and the centerCover.Remove spark plug cap and spark plug.Install compression gauge.Full open the throttle valve, and rotate theengine by means of stepping thekick-starting lever.CautionRotate the engine until the reading in thegauge no more increasing.Usually, the highest pressure reading will beobtained in 4 7 seconds.Spark plug capCompression pressure: 9.5 0.5 bar.Check following items if the pressure is toolow:l Incorrect valve clearancel Valve leakingl Cylinder head leaking, piston, piston ringand cylinder worn outIf the pressure is too high, it means carbondeposits in combustion chamber or pistonhead.Gear teethDRIVING SYSTEMDRIVING BELTRemove left side cover.Remove mounting bolt located under aircleaner.Remove 9 bolts of the engine left crankcase.Remove the left crankcase cover.Check if the belt is crack or worn out.Replace the belt if necessary or in accordwith the periodical maintenance schedule toreplace it.Width limit: above 17.2 mmClutch padStart the motorcycle and gradually increasethrottle valve openness to check clutch padoperation.If the motorcycle moves with shaking, thencheck its clutch pad for wearing. Replace itif necessary.WidthClutch padClutch2-7

2. MAINTENANCE INFORMATIONCrankcase blow-by over-flow pipeReplacement for every 1000km1.Open the stopper2.Drain the oil3.Install the stopperRemove dipstick to check the oil level. If oillevel is below the lower limit mark, add oil tothe specified upper limit mark.2-8LONG-IIA

-08: 3. LUBRICATION SYSTEMLCNl:ii JIAOIL FLOW DIAGRAM . 3-1GENERAL INFORMATION . 3-2TROUBLESHOOTING . 3-2ENGINE OIL . 3-3CLEANING ENGINE OIL STRAINER .3-3OIL PUMP.3-4GEAR OIL .3-6OIL FLOW DIAGRAMValve rockerarmForcedly lubricationCamshaftScoop lubricationInner passageConnecting rodForcedlylubricationCrankshaftOil strainerOil pump3-1

3. LUBRICATION SYSTEMLCJNl:ii JIAGENERAL INFORMATIONThis chapter contains maintenance operations for the engine oil pump, engine oil andgear oil.Oil viscositySpecificationsEngine oil quantityDisassembly 800 c.c.Replacement 700 c.c.lOil viscositySAE 15W-40 or equivalentUse SAE 5W-40 whenoutside temperature isbelow 0 .Gear Oil quantity0Disassembly 140 c.c.Replacement 120 c.c.·20-100102030Oil viscosity of gear oil SAE 80W-90 (RecommendAPI GL-4)ItemsOil pumpInner rotor clearanceClearance between outerrotor and bodyClearance between rotorside and bodyTorque valueEngine oil drain plugEngine oil filter screen capGear oil drain boltGear oil filling boltOil pump fixing screwsStandardunit : mmLimit-0.12-0.120.05 0.100.2020 26N.m13 17N.m10 15N.m10 15N.m8 12N.mTROUBLESHOOTINGLow engine oil levellOil leakinglValve guide or seat worn outlPiston ring worn outLow Oil PressurelLow engine oil levellClogged in oil strainer, circuits or pipeslOil pump damage3-2Dirty oillNo oil change in periodicallCylinder head gasket damagelPiston ring worn out40C

LCJNGi.JIA3. LUBRICATION SYSTEMENGINE OILTurn off engine, and park the motorcycle inflat ground with main stand.Check oil level with oil dipstick after 3-5minutes.Do not rotate the dipstick into engine aschecking.If oil level is nearly low level, fill outrecommended oil to upper level.DipstickOil ReplacementCautionDrain oil as engine warmed up so thatmake sure oil can be drained smoothly andcompletely.Place an oil pan under the motorcycle, andremove oil strainer cap.Make sure if the aluminum washer of thedraining bolt is damaged. If so, replace itwith new one.Install the drain plug and tighten it.Torque value: 20 26 N.mOil drain plugCLEANING ENGINE OIL STRAINERRemove the oil strainer cap.Remove oil strainer and spring.Clean oil strainer (recommended usingcompressed air to clean dirty foreign).Check if the strainer and O-ring of the oilstrainer are broken. Replace with new one iffound.Install the oil strainer and spring.Install the oil strainer cap and tighten it.Torque value: 13 17 N.mFill out oil to the oil filler (Oil viscosity SAE15W-40)Use SAE 5W-40 when outside temperatureis below 0 .Engine oil quantity: Replacement 700 c.c.Oil strainer capoil strainerspring3-3

3. LUBRICATION SYSTEMOIL PUMPOil Pump RemovalRemove the alternator (refer to chapter12).Remove the engine right crankcase cover.Make sure that the pump axle can be rotatedfreely.Remove the oil pump driving gear nut.Remove the oil pump .Oil Pump InspectionCheck the clearance between oil pump bodyand outer rotor.Limit: below 0.12 mmCheck clearance between inner and outerrotors.Limit: below 0.12 mm3-4

- "" LCNl:ii JIA3. LUBRICATION SYSTEMCheck clearance between rotor side faceand pump body.Limit: below 2.0 mmOil Pump Re-assemblyInstall inner and outer rotors into the pumpbody.Align the indent on driving shaft with that ofinner rotor. Install the driving shaft.Install the oil pump cover and fixing pinproperly and then tighten screw. (1 screw)Oil pump bodyouter rotorDrive shaftinner rotorFixing pinOil pumpcoverOil Pump InstallationInstall according to the reverse procedure ofremoval.3-5

3. LUBRICATION SYSTEM0LONm:.JtAGEAR OILOil Level InspectionPark the motorcycle on flat ground with mainstand.Turn off engine and remove both gear oilfilling bolt and gear oil draining plug.Remove gear oil filling bolt and place ameasurement cup under the draining plug.Remove the oil draining plug and the pourgear oil into the measurement cup.Measure the gear oil quantity if withinstandard value.Add specified gear oil if the oil level too low.Standard quantity: 140 cc.Replacement: 120 cc.Gear Oil ReplacementRemove the gear oil filling bolt and itsdraining plug and then drain oil completely.Install the draining plug and tighten it. (Makesure if the plug washer is damaged. If so,replace it with new one.)Torque Value：10 15 N.mAdd new gear oil (120 c.c.) from the gear oilfilling hole and then install the gear oil fillinghole bolt after added oil. And then, tightenthe bolt.Torque Value: 10 15 N.m※Recommended to apply with SAE80W-90. (Recommend API GL-4)Start engine and run it for 2 3 minutes.Turn off engine and check if oil leaking.3-6Gear oil draining plug

- 4. ELECTRONICALLY CONTROLLED CARBURETOR SYSTEMLDNa.J LAECS illustration .4-1Precautions in operation . 4-2ECSGeneral Information . 4-3ILLUSTRATION(Oxygensensor)ECU(Bectronically controlledc.arbure·tor)t Dutyfactor solenoid(Al)valve )(catalyst )(Engine. peed sensor)4-1

4.ELECTRONICALLY CONTROLLED CARBURETOR SYSTEMGeneral InformationCautions Do not bend or twist throttle valve cable. Damaged cable will make unstable driveability. When disassembling fuel system parts, pay attention to O-ring position, replace with newone as re-assembly There is a drain screw in the float chamber for draining residual gasoline. Do not disassemble automatic by-starter and air cut-off valve arbitrarily.SpecificationItemMain jetSpecificationSpeed limited:45km/h86#Speed limited:25km/h86#Speed limited:30km/h86#Pilot Jet33#Needle Jet2.1 mmLevel in float chamber21.5 0.5 mmFloat needle1.6 mmMass of float7.2g 0.1 gIdle speed2000 100 rpmFuel quantity adjustment screw2Jet needle3r21Throttle handle free play2 6 mmTorque valueFuel valve tightening nut: 1.5 2.0 Kgf-mToolSpecial service toolsVacuum/air pressure pumpGeneral service toolsFuel level gauge4-21/2 1/2

LCINl'!S.JIA4. ELECTRONICALLY CONTROLLED CARBURETOR SYSTEMCARBURETOR REMOVALRemove the luggage box.Loosen the adjustment nut and fixing nut ofthrottle valve cable, and release the cablefrom carburetor.Remove fuel pipe, vacuum hose.Disconnect auto by-starter connector.Disconnect gulp valve connectors.Disconnect TPS controller connector.Release the clamp strip of air cleaner.Release the clamp strip of carburetor isolator.Take the carburetor out.VACUUM CHAMBERRemovalLoosen drain screw, and drain out residualfuel in float chamber.Remove screws (2 screws) of vacuumchamber cover and the cover.4-3

5. REMOVAL OF ENGINEMECHANISM DIAGRAM . 5-1OPERATIONAL PRECAUTIONS . 5-2MECHANISM DIAGRAM3.5 4.5kgf-m4.5 5.5kgf-m4.5 5.5kgf-m2.4 3.0kgf-mo,/ -- 114.5 5.5 kgf-m5-1

5. REMOVAL OF ENGINEOPERATIONAL PRECAUTIONSGeneral InformationEngine must be supported by a bracket or adjustable tool in height.The following parts can be serviced with the engine installed on the frame.1. Carburetor2. Driving disk, driving belt, clutch, and transporting disk3. Final reduction gear mechanismSpecificationSpecificationEngine Oil CapacityGear Oil CapacityDisassemble800 c.c.Replacement700 c.c.Disassemble140 c.c.Replacement120 c.c.Torque ValuesEngine suspension bolt (frame side)Engine suspension nut (engine side)Bolt of rear shock absorber upper connectionBolt of rear shock absorber lower connection5-245 55N. m45 55 N. m35 45 N. m24 30 N. m

6. CYLINDER HEAD / VALVELCi .JlACOMPONENT STRUCTURE .GENERAL INFORMATION .TROUBLESHOOTING.CYLINDER HEAD REMOVAL .CAMSHAFT REMOVAL .6-16-26-26-36-5CYLINDER HEAD DISASSEMBLY . 6-6CYLINDER HEAD INSPECTION . 6-7.CYLINDER HEAD REASSEMBLY . 6-8CYLINDER HEAD INSTALLATION. 6-9VALVE CLEARANCE ADJUSTMENT. 6-10COMPONENT STRUCTURE Prevention Modification Screw8 12 N.mUDI'13 17 N.m @7 11 N.mQ- - --rr.I1IIr' (I) '-10 12 N.m'.-," !-1 -/ '8 12 N.m12 16 N.m20 25 N.m8 12 N.m6-1

6. CYLINDER HEAD / VALVEGENERAL INFORMATIONŸŸThis chapter is contained maintenance and service for cylinder head, valve, andcamshaft as well as valve rocker arm.Cylinder head service cannot be carried out when engine is in frame.SpecificationCamshaftRockerarmunit: mmItemStandardLimitCompression pressure9.5 0.5barAt 550rpm-Intake25.54 25.7025.14Exhaust25.14 25.3024.74ID of valve rocker arm10.000 10.01510.10OD of valve rocker arm shaft9.972 9.9879.90Intake4.970 4.984.90Exhaust4.955 4.974.905.000 5.0125.030Intake0.03 0.070.08Exhaust0.08 0.120.1331.8 33.031Height of cam lobeOD of valve stemID of GuideValveClearance betweenvalve stem and guideFree length of valvespringTROUBLESHOOTINGCylinder head cover boltCamshaft sprocket boltBolt of timing chain auto-adjusterSpark plugCylinder head nutValve adjustment fixing nutsTOOLSSpecial service toolsValve reamer: 5.0mmValve guide driver: 5.0mmValve spring compressor6-28 12 N.m20 25 N.m8 12 N.m10 12 N.m12 16 N.m7 11 N.m

6. CYLINDER HEAD / VALVECYLINDER HEAD REMOVALRemove the engine from the vehicle(Refer to chapter 5).Remove the shroud of the engine.Remove the crankcase blow-by systemhose from the cylinder head.Remove the cylinder head cover 4 Cat nutand then remove the cylinder head cover.Cat nut 4Loosen the bolt of camshaft chain adjusterin a counter-clockwise motion for releaseadjuster.BoltRemoved cam chain adjustment bolt. Andthen removed the chain adjuster (bolts 2)Chain adjusterRemoved cylinder head side cover.Cylinder head side cover6-3

6. CYLINDER HEAD / VALVETurn the flywheel in counter-clockwisemotion with T type wrench until the “T”mark on flywheel aligned with the mark onthe crankcase so that the hole on thecamshaft sprocket is forward up and pistonis at TDC position.T markTDC markRemove camshaft sprocket bolt(bolt).Remove the cam sprocket and cam chain.BoltRemoved the bolts of the left side of thecylinder head between cylinder headand cylinder(bolt 2).Bolt 2Removed cylinder head fixed nut (nuts 4).Nuts 46-4

6. CYLINDER HEAD / VALVELONOIJ.lARemove cylinder head.CautionLoosen the nuts diagonally by 23 sequences.CAMSHAFT REMOVALRemove the fixed (bolt 1), then removethe camshaft.CamshaftRemove the valve rocker arm shaft.Remove the valve rocker arm.6-5

6. CYLINDER HEAD / VALVECYLINDER HEAD DISASSEMBLYUse the special tool of compress valvesprings.Remove valve spring removedlocation pin.CautionDo not over-compressed valve springs.Avoiding weaken the spring flexibility.Put out the spring stopper, spring andvalve. Remove the valve cotter ,valvespring retainer ,valve oil seal .Clean carbon deposits in combustionchamber. Clean residues and foreign materialson cylinder head matching surface.CautionDo not damage the matching surfaceof cylinder head.ICAMSHAFT INSPECTIONInspect cam lobe height for damaged.Service LimitIN: Replacement when less than 25.14 mmEX: Replacement when less than 24.74mmInspect the camshaft bearing forlooseness or wear out. If any, replacewhole set of camshaft and bearing.Camshaft bearing6-6

6. CYLINDER HEAD / VALVEVALVE ROCKER ARM/ SHAFTINSPECTIONMeasure the valve rocker arm I.D.Service Limit: Replace when it isabove 10.100 mmMeasure the active O.D. of the valverocker arm shaft.Service Limit: Replace when it isabove 9.90 mmCalculate the clearance between therocker arm shaft and the rocker arm.Service Limit: Replace when it isabove 0.10 mmCYLINDER HEAD INSPECTIONCheck if spark plug and valve holes arecrack. Measure cylinder head flat with astraightedge and flat feeler gauge.Service limit: below 0.05mmValve spring free lengthMeasure the free length of intakeand exhaust valve springs.Standard:31. 0mmThe rrow pitch of the sprtng shaR face lo lhecombustion chamber.6-7

6. CYLINDER HEAD / VALVEValve stemCheck if valve stems are bend, crack orburn. Check the operation condition of valvestem in valve guide, and measure & recordthe valve stem outer diameter.Service Limit: IN 4.900mmEX 4.900mmValve guideCautionBefore measuring the valve guide,clean carbon deposits with reamer.Special Service Tool: 5.0mm valveguide reamerMeasure and record each valve guideinner diameters.Service limit: 5.030mmThe difference that the inner diameter ofvalve guide deducts the outer diameterof valve stem is the clearance betweenthe valve stem and valve guide.Service Limit: IN 0.13mmEX 0.13mmICYLINDER HEAD REASSEMBLY@,Lubricate valve stem with engine oil,and then insert the valve into valveguide. Install new valve stem oil seal.Install valve springs and retainers.face down to combustion chamber.L Io//Q'/?J.\\" ""'-Valve cottersCautionAThe closed coils of valve spring shouldValve spring retainerSpringIIyOil seal ValveL6-8

6. CYLINDER HEAD / VALVEUse valve spring compressor to pressvalve spring.Install valve split locks and release thevalve compressor.CautionIn order to avoid to loosing spring tension,do not compress the spring too much. Itslength is based on the installation of latch.Special tool: valve spring compressorTap valve stem to make valve retainerand valve stem sealing properly.CautionPlace and hold cylinder head on to workingtable so that can prevent from valvedamaged.CYLINDER HEAD INSTALLATIONInstall the lock pins and new cylinderhead gasket onto the cylinder head.Install the camshaft chain plate.pinsClinder head gasketAt first, tighten the 4 nuts on the cylinder topand then tighten the 2 bolts on the left sideof cylinder head.With T type wrench to turn crankshaft in aclockwise motion so that the “T” mark onthe flywheel aligns with the mark oncrankcase. (piston is at TDC position).Install the cylinder head nuts and tighten it.Torque value: 12 16 N.mInstall the cylinder head left side boltand tighten it.Torque value: 8 12 N.mNuts 4Bolts 26-9

6. CYLINDER HEAD / VALVEInstall the spark plug and tighten it.Torque value: 10 12 N.mLONl:l.llASpark plugApply with oil onto the thread of cylinderhead bolts and tighten the bolts indiagonally for 2-3 sequences.Do not over tightening the bolts to avoidthe cylinder head deformation, noisecreated or leaking so that effectsmotorcycle’s performance.Install the cam shaft. Place the TDC marks ofthe cam sprocket at same level of the top-endof cylinder head. The other single hole of thecam sprocket is in upward. Then, install thecam chain onto the cam sprocket. Tighten thebolts of the cam sprocket. Install the cylinderhead side cover."T " markTorque value: 20 25 N.mTurn the cam chain adjuster in clockwisemotion so that the adjuster is pushed out tocontact the cam chain plate tightly. Tightenthe bolt cap of the adjuster adjustment hole.CautionThe O-ring must be installed into glove.VALVE CLEARANCE ADJUSTMENTLoosen valve clearance adjustment nuts andbolts located on valve rocker arm.Measure and adjust valve clearancewith feeler gauge.After valve clearance had been adjustedto standard value, hold adjustment boltand then tighten the adjustment nut.Standard Value: IN 0.05 0.02mmEX 0.10 0.02mm6-10BoltChain adjuster

7. CYLINDER/PISTONLClNICJI.J IACOMPONENT STRUCTURE . 7-1GENERAL INFORMATION . 7-2TROUBLESHOOTING . 7-2CYLINDER REMOVAL . 7-3LIPISTON REMOVAL . 7-5PISTON RING INSTALLATION . 7-7PISTON INSTALLATION . 7-8CYLINDER INSTALLATION . 7-8COMPONENT STRUCTURE-,-8 12 N.m8 12 N.m :,::.C . ---------- ----"ol 7-1

0 7. CYLINDER/PISTONGENERAL INFORMATIONŸ Both cylinder and piston service cannot be carried out when engine mounted on frame.Specificationunit: mmItemStandardLimit37.00 30Top ring0.020 0.0600.0902nd ring0.020 0.0600.090Top ring0.10 0.250.5002nd ring0.10 0.250.650Oil ring0.20 0.70－OD of piston36.970 36.99036.920Piston OD measuremnet positionLower-end up7mm of pistonshirtIDBend/wrap ageCylinderClearance betweenpiston and ringsRing-end gapPiston/Piston ringClearance between piston andcylinder0.025 0.0350.10010.004 10.01010.040OD of piston pin9.994 9.9989.980Clearance between piston and piston pin0.006 0.0160.0210.016 10.03410.050ID of piston pin holeID of connecting rod small-endTROUBLESHOOTINGLow Or Unstable Compression Pressurel Cylinder or piston ring worn out.l Compress pressure to high.l Too much carbon deposited incombustion chamber and piston.Smoking in Exhaust Pipel Piston or piston ring worn out.l Piston ring installation improperly.l Cylinder or piston damage.Knock or Noisel Cylinder or piston ring worn out.l Carbon deposits on cylinder headtop-side.l Piston pin hole and piston pin wear out.Engine Overheatl Carbon deposits on cylinder head topside.7-2

LONQ.llA7. CYLINDER/PISTONCYLINDER

7 Brake & free play check I I 8 Steering handle check I I 9 Cushion operation check I I 10 Every screw tightening check I I 11 Gear oil check for leaking I I 12 Spark plug check or change I I R 13 Gear oil change R Replacement for every 5000km 14 Frame lubrication L