19LX300-6A LX178MN Engine

S ummar y……………………………………………………………………………………………..........................…….........................................19.2
Lubricating system……………………………………………………………………………………………..............................…….....................19.3
Checking and adjustment……………………………………………………………………………………………......................…….................19.4
Cooling system……………………………………………………………………………………………..........................……........…....................19.7
Cylinder head and valves………………………………………………………………………………..............................…............................19.7
Cylinder body and piston……………………….………………………………….................................................................................19.13
Clutch component………………………………………………………………………………….............................................……................19.16
Gearshift assembly…………………………………………………………………………………...............................…….............................19.19
Magneto and electrical starting component……………………………………………………………………..........………...................19.20
C rankshaft and transmission assembly………………………………………………………………………….........................................19.23
Failure judgement……………………………………………………………..........................................................................................19.26

19.1
 Standard torque
Summar y
No. Name Specification Torque N·m
Issues need pay attention to in maintenance
1 Spark plug M10 15～20
1. The
Loncin recognized or recommended spare parts, lubricant or
2 Bolt on cylinder head cover M6 8～12
other auxiliary material must be adopted. In case the material for
maintenance falls shorting of meeting Loncin specification or requirement,
3 Bolt of camshaft bracket M6 10～15
the motorcycle may damage.
2. The washer, seal parts or split pin need be replaced after disassembled 4 Cylinder body fastening bolt M6 10～15
or need re-assembly.
3. Fasten the bolt and nut by opposite angle sequence by 2~3 times until 5 Cylinder body fastening bolt M10 40～50（Pre-fastening）
to stipulated torque. 50～60（Final）
4. Inflammable cleanser is not allowed when washing the parts. Coat 6 Timing driven sprocket M6 10～15
the moving surface of parts with lubricant before re-assembly.
5. Check and confirm the correct re-assembly of each parts after installed 7 Tensioner fastening bolt M6 10～15
by turning, moving or operation.
8 Oil tube bolt M8 15～18

9 Primar y gear fastening nut M12 90～100

10 Clutch fastening nut M12 70～80

11 Impellor locking nut M6 10～15

Main technology parameters 12 Oil controller valve M12 10～15

Type 13 Ratchet plate locking bolt M6 8～12

Items Yf300
14 Rotor fixing bolt M12 100～120
Type LX178MN
15 Gearshift drum plate bolt M6 10～15
Specification Single cylinder, 4 strokes, Standing engine,
Water cooled, 4 valves, Double camshaft on top 16 Check plate bolt M6 10～15
Max. power and its (19.3±5%)kW/(8500±1.5%)rpm
17 Gearshift arm bolt M10 25～30
M a i n Max. torque and its (24.5±5%)N·m/(7000±1.5%)rpm
para
18 Oil drainage bolt M12 15～20
mete M i n . f u e l ≤340 g/km·h
rs
19 Chain adjuster plate pin axis M8 25～30
Min. Idling speed （1500±150）rpm

Bore 78mm
Except the torque above, other fastening torque is as below：

Piston stroke 61.2mm

No. Name and specification Torque N·m
Displacement 292.4ml
1 5mm Bolt and nut 5～7
M a i n Compression ratio 11.0：1
stru 2 6mm Bolt and nut 10～15
c t u r Air inlet Double camshaft at top
3 8mm Bolt and nut 15～20
Ignition way CDI
4 10mm Bolt and nut 25～35
Lubrication way Pressure splash
5 12mm Bolt and nut 30～40
Cooling way Water cooling
6 5mm screw 3.5～5
Clutch type Manual clutch, wet multiple
7 6mm screw 8～12
Gearshift International

Primar y deduction ratio 2.8 Periodical maintenance table

1st gear 3 Milage meter km
Maintenance times
Tran
s m i s 2nd gear2nd gear2nd 2 Items 2000 5000 10000 15000
sion
3 rd gear 1.5
Clutch adjust √ √ √ √ √
th
4 gear 1.25
Clutch plate - check √
1.05
Spark plug – clean, √ √ √ √ √
0.905
Valve clearance √
Engine starting Electrical only Air filter clean Each 1000km

Ignition curve or working 1700±200r/min 时0˚ ± 1˚ Air filter replace When damaged
5000± 200r/min 时 25˚ ± 1˚
Spark plug cap clean Each 4000km　
Spark plug Resistance B8RC

A i r Open BTDC 0° （Open 1）

Oil filter replace √ √ √
inle Oil replace √ √ √
Close ABDC 35°（Close 1）
Sprocket wheel check
√
A i r Open BBDC 12°（Open 1） Coolant replace Each 2 years
exha
u s t √
p o r t Close ATDC 16° （Close 1）
Heat radiator check √
Fuel system clean √ √ √ √ √
Lubrication specification 15W/40-SG（Summer）10W/30-SG
Bolt, nut, wahser check √ √
Lubrication capacity (mL) 1500±100mL
Lubricant system check √ √ √ √ √
Engine net weight (㎏) 34±1kg
19.2
 The motorcycle shall be maintained on time.
The maintenance shall be done by Loncin ser vice station, in case
need be conducted by your self, please refer to this manual.

Lubrication system
Issues need pay attention to.
This chapter introduce the washing, checking and replacement for each
parts of lubrication system. Checking and washing could be done without
disassembling the engine, but the old lubricant need be drained off before
this work.

Troubleshooting
1). Fast lubricant consumption
1. Engine oil leakage
2. Piston rings wear out
3. Guiding rod of valves wear out
4. Oil shield cover wear out or damage
3). Abnormal lubrication
1. Too low the oil level
2. Oil passage or screen blocked
3. Oil pump damaged
Engine lubrication system
1. Upper scale mark
2). Dirty lubricant 2. Lower scale mark
1. Replace oil without according to maintenance table 3. Oil view window
2. Thread of oil filling-up port damaged
Replace the lubricant
Replace the lubricant before the engine completely cooled down for making
sure quickly and totally drain off the old lubricant in crankcase. Lay an
oil dish under the engine when replacing, then screw off the oil drainage
bolt A and drain the oil. Check the washer of drainage bolt is working,
replace if damaged. Screw up the drainage bolt with washer after the oil
drained off.
The fastening torque：18N·m
Fill up new lubricant and check the oil level.

Lubricant is important to engine performance and working life, so the

selection must be according to stipulation, in which common oil, gear
oil or that made of plant is not allowed. The original lubricant of this
motorcycle is 15W/40SG of gasoline engine grade.

Requirement for oil volume：

The new engine need fill up by 1.5L; In case the secondary oil filter without
replaced when filling up, by 1.3L; In case the oil filter replaced, fill up by 1.4L.

Replace the secondary oil filter

Remove the cover of secondary oil filter and take out the filter A.
Replace for new one and assemble its cover.
In case other lubricant was adopted, whose grade must reach SG grade
or higher, and adhesion according to local temperature in attached map.
Drain off the old lubricant, then clean and wash up the crankcase by
kerosene before new filling-up.

Check the lubricant

In case the engine is under running, turn the engine off and wait for minutes
until the oil reach the bottom of crankcase. Lay the engine vertically to the
ground and observe the oil through its view window for marking sure its
level is within the upper and lower scale marks.
In case the oil level is higher than scale mark 1, drain off the surplus oil.
In case is lower than the scale mark 2, supplement for more.

19.3
Repla c e t h e p r e ss u r e r e l e a s i n g v a l v e
Remove the right crankcase cover and screw off the pressure releasing
valve A, then replace for a new one and screw up.
Fastening torque: 15 N·m
Oil pump assembly
Wash up the metal chips and dirt on oil screen A. Coat the new oil pump
with lubricant. Check and confirm the positioning pin B , seal ring C, and
oil screen is assembled.
Finally assemble the oil pump and fasten the screw.

Oil pump disassembly

Remove the elastic circlip B, washer C, and oil pump shaft.
Remove screw E on oil pump cover and the cover A.
Remove the inner and outer rotor.

Check the oil pump

Check oil pump body A, outer rotor B, inner rotor C, and cover D after the
oil pump broke up, replace the corresponding part or the whole oil pump
in case the parts above damaged.

Oil pump disassembly

Remove the right crankcase cover, screw A and oil pump B.

Wash the oil screen

Remove the right crankcase cover and wash up the oil screen.
Washing by gasoline is not allowed. Check the damage, replace if necessary.
Assemble the screen back to the crankcase, and install its cover.

Check and adjustment

Issues need pay attention to

This chapter introduce the check and adjustment for each part of Loncin
YF300 engine while attaching their corresponding technological requirement.

Technology requirement

Spark plug B8RC

Spark plug 0.6～0.7

Inlet：0.1～0.19
Valve gaps
Exhaust：0.15～0.24

Spark plug S p a r k p l u g

Idling rotation 1500±150r/min

C y l i n d e r ≥1200kPa

19.4
Spark advance angle Spark plug
Remove the spark plug by socket wrench and visually check the damage on
insulator and ablation on the pole, in case it is, replace.
Check the pole gaps by thickness gauge whose gap between spark plug
poles shall be 0.6～0.7mm.

2
1

Carefully adjust the gap, then clean up the carbon buildup and dirt
by spark plug washer or steel wire.

10
Valve cleatance
Note: Adjust the valve clearance when the engine is cold.

Remove the cylinder head cover, view hole cap A and decorative cap B.

19.5
Align the timing mark
Turn the crankshaft anticlockwise and observe through the view hole
on left front cover, which make the timing mark (T scale mark) on rotor
align with the groove on view hole cap, when the piston is on the upper
stopping point of compression stroke.

Cylinder pressure test

Pre-heat the engine and turn off, remove the spark plug and install
pressure tube B on whose position, and install pressure gauge A on
the tube, then completely open the choke and throttle, and turn on
the staring motor for 4~6 times.

Timing mark“—”on the camshaft is paralell with contact surface of cylinder head.
（Note：The air inlet cam corresponding to scale mark“IN”，while the exhaust to
“EX”).
Check the valve clearance
Insert the thickness gauge within camshaft A and tappet B
for checking the valve clearance.
Air inlet valve：0.1～0.19
Air exhaust valve：0.15～0.24
In case valve clearance incorrect, adjustment is necessar y.
Adjust the valve clearance
Remove the camshaft bracket, camshaft A and tappet B, then the valve adjusting
Note: Check each joint of pressure gauge
shim C; and select a new shim according to requirement of valve clearance.
When assembling the adjusting shim, the side with mark faces to valve tappet;
to confirm the air leakage. Repeatedly start the engine untill pressure
Then assemble the tappet and camshaft which ensure the timing position; gauge stopped rising. The Max. daga could be got normally after started
Measure the valve clearance after adjusted. In case re-adjustment is needed, adjust for 4~6 times.
again according to steps above until it correct; Assemble the camshaft bracket and Cylinder compression：≥1100kPa
cylinder head cover.

19.6
Cooling system Assemble cooling pump cover (Note: Fasten 2 pcs of bolts on positioning pin
position for ensuring flat contact surface).
Issues need pay attention to
Assemble and repair the cooling pump after its cover removed. Damage
on both contact surface of the cover is not allowed.

Troubleshooting

The failure of engine water cooling system may lead to engine overheat or
cold which bad for its performance, in this case, timely maintenance and
troubleshooting for the cooling system is necessary.
Select the coolant according to local temperature which with difference.
The ice point of coolant shall be lower than local environmental temperature.
Running or hard water for substitution is now allowed. The coolant is with
function of cooling, antiscale, antirust and rising the boiling point, while the
running water can only cool the engine, in this case, adopt running or hard
water may lead to pump shaft rust, scaling and poor heat radiation which
makes engine overheat.
Check if the coolant in the water tank decreased when the engine is cold, in
case decreased much, which indicates the leakage, but need further inspection
for confirming inside or outside leakage. Judge the inside leakage through
viewing the oil color, in case the coolant entered the oil, which may emulsify
and the color may change to white, at this moment, disassemble the engine
and check the related position of water passage such as cylinder head,
cylinder body, gasket or right crankcase cover.
Judge the outside leakage through viewing the flowing trace on joints of
cooling pump cover, heat radiator, auxiliary water tank, and water tube.

Disassembly of cooling pump cover

Lay a box under the engine before disassembling the cooling pump, screw
off the drainage bolt on engine and drain off the coolant.
Remove the fastening bolt on the pump cover and remove the cover.
Remove the impellor.
Check the damage on impellor and abnormality, abrasion or damage
of seal surface on cooling seal static or dynamic ring, in case it is, replace.
Check damage on end surface of cooling pump, in case it is, replace.
Cylinder head and valves
Issues need pay attention to
General rules
Remove the engine before maintaining camshaft, cylinder head, valve
tappet. Coat the camshaft and tapped with lubricant before re-assembling
for basic lubrication.

Size and specification of each part

Items S t a n d a r d Repair limit

I n l e t c a m 36.20～36.30 36.10

Exhaust cam 36.17～36.27 36.07

Camshaft C a m s h a f t 22.967～22.980 22.94

C a m s h a f t 23.000～23.021 23.08

Gap between 0.020～0.054 0.15

Inlet valve 0.7 0.45

Exhaust valve 0.8 0.5

Inlet valve rod 4.475～4.49 4.460

Exhaust valve rod 4.455～4.470 4.440

Inlet guiding rod 4.510～4.522 4.59

Valve
Exhaust guiding rod 4.510～4.522 4.59

Gap between inlet 0.02～0.047 0.07

Gap between 0.04～0.067 0.08

Assemble the cooling pump Inlet valve plate 28.9～29.1 /

Press and assemble the water seal static ring of cooling pump on the right Exhaust valve plate 24.9～25.1 /
cover while the dynamic ring A on impellor (Suitably coat outer surface of
rubber ring B on dynamic ring with sealing glue C)，the sealing surface Inlet 0.10～0.19 /
matched with static ring face outwards.
Lock up the impellor of cooling pump Valve gap
Fastening torque：10N·m Exhaust 0.15～0.24 /

19.7
 I n n e r 36.2 34.5 Disassembly of camshaft.
V a l v e Remove the cylinder head cover
spring O u t e r 41.1 39.4 Remove the bolts of tensioner on cylinder head,

Chain length（20 links） 127.0～127.4 138.9 and then remove the tensioner.
Remove the connective bolt on the bracket
Remove the cam bracket
Trouble shooting Remove the chain
Remove the camshaft
Low air pressure in cylinder： Blue smoke emission
1 Valve 1. Guiding rod abrasion
Incorrect valve gaps 2. Oil shield leakage or damage
Poor valve sealing 3. Cylinder head gasket leakage
Incorrect valve timing 4. Wide piston ring gap
Valve spring cracked
2. Cylinder head Noisy
Poor connection between spark plug and cylinder head 1.Incorrect valve adjustment
Cylinder head gasket leakage or damage 2. Valve seize up or valve spring cracked
Cylinder with crack or sand hole 3. Camshaft abrasion
3. Cylinder body and piston 4. Too long the timing chain
Wide piston ring gap or cracked 5. Incorrect valve timing
Piston with crack or damage 6. Timing chain tensioner abrasion or damage
oo big the inner bore or with sand hole 7. Timing sprocket wheel teeth abrasion
2

Disassembly of cylinder head cover

Remove the fastening bolt A on cylinder head. Remove the cylinder head cover B.

Note：The timing chain drop into the crankcase is not allowed.

Disassembly of camshaft bracket

Remove the cylinder head cover, connective bolt of bracket, and finally
remove the camshaft bracket.

Check the camshaft

Check the rising distance of each cam.
Measure the protrusion length A on the cam by micrometer
to check the abrasion.

19.8
 Disassembly of cylinder head.
Remove the air inlet tube.
I n s p e c t i o n Standard Maintenance Remove the water tube joint.
Remove the cylinder head cover.
Inlet cam 36.20～36.30 36.10 Remove the camshaft bracket.
Remove the camshaft.
Exhaust cam 36.17～36.27 36.07 Remove the bolt connects cylinder body and that on the sides.
Finally remove the cylinder head.

Check the trunnion of each cam for confirming the abrasion.

Air inlet and exhaust cam
Standard：22.967～22.980
Repair limit：22.94

Assemble the camshaft

Align the timing mark
Turn the crankshaft D anticlockwise, obser ve through left front over C to ensure
the timing mark A is aligned with that B (T scale line) on magneto, while the piston
is at the upper stopping point of compression stroke.

Disassembly of the cylinder head

Press down the valve spring by its disassembler and remove the valve clip.
Release the valve disassembler，remove the valve spring, its base, the inner
spring seat ring, and the valve.

Note: For avoiding permanent distortion of valve spring, excessive pressing is not
allowed, only need remove the valve and its clip.
Mark all the removed parts for ensuring their original position when re-assembling.

When assembling the camshaft, the timing scale mark “—”is parallel with
contact surface of cylinder head.

（Note：Inlet cam corresponds to scale line“IN”，while the exhaust one to

“EX”）
Coat the cam and its trunnion with lubricant.

19.9
 Clean up the residuals on surface of cylinder head by scraper which is not allowed.

Check the cylinder head

Check if there is crack on spark plug hole or valve base.

Check if there is distortion on cylinder head, and check the flatness of cylinder
head by flat surface piece A and feeler gauge B.

Repair limit 0.05

Check the valve and its guiding tube

Check the distortion, burning on each valve or abnormal abrasion on its guiding rod.
Check the valve moving in its guiding rod and their outer diameter,
Insert each valve to its guiding rod to observe the moving.

Standard Maintenance limit

Air inlet valve 4.475～4.49 4.460

Air exhaust valve 4.455～4.470 4.440

Check the valve spring

Measure the free length of inner and outer spring.

Repair limit：（Inlet and exhaust）

Measure the inner diameter of each guiding rod by inner diameter micrometer or
other special tools, finally calculate and get the gaps between valve rod and its Inspection items Standard Maintenance limit
guiding tube.

Valve inner spring 36.2 34.5

Inspection items Stan Mainte

Valve outer spring 41.1 39.4

Inlet guiding tube 4.510 4.59

Exhaust guiding tube 4.510 4.59

Gap between inlet valve and guiding tube 0.02 0.07

Replace the valve guiding tube

Gap between inlet valve and guiding tube 0.04 0.08 Firmly fix the cylinder head and remove the valve guide tube
by its disassembler tool A from valve hole outwards.

Note：No damage on cylinder head is allowed when

Note: Clean up the carbon buildup inside the guiding tube before measuring its disassembling the valve guide tube.
inner diameter. In case the valve guiding tube need be replaced, the surface of
valve base need grinding once again.
Clean up the carbon buildup in the combustion chamber.

Combustion chamber

19.10
Press and assemble the new guiding tube and o-ring on cylinder head, Valve base repair
and ream the new guiding tube.
Note: Coat the reamer A with cutting oil when reaming. Milling cutter of valve base
Turn the reamer when it assembling or take out. 3 kinds of milling cutter with different angle
Finally wash the cylinder head by cleanser, and clean up the metal chips on it.

Mill the upper ring belt of valve base by milling cutter of 32°.

Check the valve base

Measure the door line diameter of valve base ring, whose width is E.

Standard data of door line diameter D： Air inlet valve：28.3～28.5

Air exhaust valve：24.2～24.4
Standard data of door line width E： Air inlet valve, Air exhaust valve 1.0～1.2

Mill the bottom ring belt of valve base by milling cutter of 60°.

In case the diameter of the width above unqualified, the base ring need repair
to reach the correct seal performance.

Finish machining the working surface of valve base by milling cutter of 45°
to reach the correct width. Working surface standard width：1.0～1.2。
Check the valves

Remove the valve and check its contact surface.

In case the surface is rough or with uneven abrasion which lead to poor
contact, the valve need be replaced.

Coat the valve base with stamp-pad ink put into valve and turn,
then remove the valve.
Obser ve and confirm the correct contact surface.
Note: Fine contact between the valve and its base
is important for engine sealing.

19.11
In case too high the valve contact surface, mill by milling cutter of 32°
to decrease.

In case too low the valve contact surface, mill by milling cutter of 60°
to rise .。

Finally mill by milling cutter of 45° until the contact surface reached the correct width.
After the valve base machined, coat with abradant, and then put into the valve for
grinding.
After grinded, wash up all the abradant residual on cylinder head, valve base and
valve guide tube.

Assemble the cylinder head

Clean up the cylinder surface after the cylinder head gasket removed.
Assemble new gasket and positioning pin.
Note: Dust or impurity drop into cylinder is not allowed.
1. Assemble positioning pin and new cylinder head gasket.
2. Assemble cylinder head, connective bolt and washer.
3. Assemble the side bolt of cylinder body.
4. Assemble valve adjusting shim and valve tappet.
5. Assemble the camshaft.
6. Assemble the positioning pin and cam bracket.
7. Assemble the tensioner.

Cylinder head assembly

Put the oil shield cover into valve guide tube before assembling valve.
Coat exhaust valve rod with lubricant
and put into guiding tube. Assemble valve spring and its base.
Note: The spring end with smaller pitch faces to cylinder head when assembling
the valve spring.
Press down the valve spring by valve disassembler, and put the valve clip into
spring base.
Note: Excessive pressing the spring is not allowed for avoiding permanent distortion,
the valve clip could be put in is enough.
Slightly knock then end of valve rod by plastic hammer to firmly trap into the groove.

19.12
 Note: Fasten the connective bolt first which from the positioning pin by turns of Standard（mm） Repair limit （mm）
Items
opposite angle; After the cap surface completely plying-up, fasten the torque to
(40～45)N·m, then the connective bolt by （50
Cylinde Bore 78.00～78.01 78.07
～55）N·m；Finally the side bolt of M6.

Outer diameter 77.950～77.97 77.805

Coat the trunnion of camshaft and valve tappet with clean
engine lubricant. Align the timing mark when assembling Pin hole inner 17.002～17.008 17.04
the camshaft.
Piston 1st ring groove 1.01～1.03 1.11

2nd ring groove 1.01～1.03 1.11

3rd ring groove 2.01～2.03 2.11

connect Smaller head hole 17.013～17.025 17.05

Piston Outer diameter 16.994.0～17.000 16.96

Gap between cylinder and 0.03～0.06 0.12

Gap from piston pin to its hole 0.002～0.014 0.02

Gap from piston pin to small 0.013～0.031 0.05

Piston 1st ring 0.97～0.99 0.9

ring
thickne 2nd ring 0.97～0.99 0.9

Gap 1st ring 0.02～0.06 0.16

from
piston 2nd ring 0.02～0.06 0.16

1st ring 0.15～0.3 0.65

Piston
ring
2nd ring 0.20～0.35 0.7
closing
Assemble the new cylinder head gasket into its corresponding groove. gap
Assemble the cylinder head with its cover. Screw up the fastening bolt on the cover. oil ring 0.2～ 0.7 1.0
Bolt fastening torque：（8～10）N·m。

Troubleshooting

Low or unstable compression Overheat

1.Cylinder or piston ring damage or abrasion 1. Carbon buildup in piston of combustion chamber
Smoky Abnormal knocking
1.Cylinder, piston or its ring damage or abrasion 1. Knocking or noisy
2.Incorrect piston ring assembly 2. Piston or cylinder abrasion
3.Piston or cylinder wall scratch。 3. Carbon buildup in piston

Disassembly of cylinder body

Remove the cylinder head (Refer to Chapter 6)

Remove the gasket and positioning pin.
Remove the cylinder body.
Note: The timing chain drops into crankcase when disassembling the cylinder is not
allowed.
Shave the residual gasket on cylinder surface by scraper.
Note: Immerse the gasket into oil will be easily break up. Damage on contacting surface
of cylinder shall be avoided when doing this work .

Note：
When assembling the seal ring of fastening bolt on cylinder head cover, the side
with metal liner plate faces upwards (This side matches the flange of cylinder head
cover bolt).

Cylinder body and the piston

Issues need pay attention to

General rules

Assemble new gasket and positioning pin before installing the cylinder.
Impurity or dust drop into crankcase is not allowed.

Specification of each parts

19.13
Check the cylinder

Check if there is abrasion or damage on the cylinder.

Measure the inner diameter of the cylinder at 3 positions such as piston stroke top A
middle position B and bottom C, which are vertical each other for 2 directions

A=10 B=60 C=100

Standard bore： 78.00～78.01
Maintenance limit：78.1

Check the piston and its rings

Measure the clearance between piston ring and its groove by thickness gauge A as
shown on left.
Measuring standard：
1st ring：0.02～0.06
2nd ring：0.02～0.06
Maintenance limit：
1st, 2nd：0.16
Remove the piston ring
Note: Damage the piston ring when disassembling is not allowed.

Disassemble the piston

Remove the piston pin circlip by the pliers.
Note: The circlip drop into crankcase is not allowed.
Press out the piston pin from piston, and remove the piston.

Insert each piston ring into cylinder and measure its clearance.
Standard：
1st ring：0.15～0.3
2nd ring：0.20～0.35
Maintenance limit：
1st ring：0.65
2nd ring：0.7
Check if there is abrasion or crack on piston or abrasion on groove of piston rings

19.14
Measure the outer diameter 5mm above the skirt part of piston
Standard： 77.950～77.97
Maintenance limit：77.805
Calculate the clearance between cylinder and piston.
Maintenance limit：0.12

Issues need pay attention to when assembling piston ring：

The opening of the 1st ring faces to air exhaust direction；
The opening of 2nd ring and separator ring of oil ring face to air inlet direction；
The inter val between the openings of 1st ring and scratch ring shall be (30~40), on the
both sides.
The oil ring constitute by 3 rings, whose clearance could be matched with that of
separator ring.
Measure the hole diameter of piston pin：
Assemble separator ring first, then the scratch ring when assembling the oil ring.
Standard： 17.002～17.008
Maintenance limit：17.04
Measure the outer diameter of piston pin：
Standard： 16.994.0～17.000
Maintenance limit：16.96

Assemble the piston rings Assemble the piston

Totally wash up the groove on piston ring, and assemble the piston ring.。
Note: Damage on piston and its ring is not allowed when assembling.
The side with mark face upwards when assembling piston ring.
The piston ring shall be freely moved after assembled.
Reversely assemble the 1st and 2nd ring is not allowed.
Assemble the piston, piston pin and the new circlip in place.
Note: When assembling the piston, the side with mark“▲”faces to air exhaust
valve.
Stagger the opening of piston and end clearance of the circlip, and replace the
circlip when re-assembling. The circlip drop into crankcase is not allowed.

19.15
 Troubleshooting

Clutch skidding when acceleration

1. Insufficient free travel
2. Abrasion on friction plate

Below is the disassembly for separated crankcase cover

In case it is a one piece right cover such as Cr6, follow the
disassembly of right crankcase cover, and the replacement
and checkiing for clutch is the same.)

Assemble the cylinder body

Assemble the new gasket and positioning pin in place.

Coat the cylinder and piston ring with oil.
Assemble the cylinder.
Note: When assembling, damage the piston shall be avoided. Chain
drops into the crankcase is not allowed.
Assemble cylinder head gasket and the positioning pin.
Assemble the cylinder head.

Remove the clutch cover

Remove the clutch cable.

Loosen the fastening bolt on clutch.
Remove the clutch cover.
Note: Remobe the clutch operation rod A when disassembling is not allowed
for avoiding damage the oil seal B, or the B need be replaced.

Clutch component

Issues need pay attention to

Assembly and maintenance could be done after the right crankcase cover
removed without remove the engine. Damage on the contact surface of Assemble the clutch cover
the cover and case body is not allowed. Impurity drop into engine is not
allowed. Assemble the positioning pin on the clutch cover.
Turn the clutch operation rod downwards.
Replace the gasket for clutch cover.
Specification of each parts Assemble the clutch cover 。
Fasten the mounting screw B
Fastening torque：（8～10）N·m

Items Standard Repair limit

Free travel 2～3 /

Thickness of 2.95～3.05 2.7

Clutch
Thickness of Max. 0.2

Main spring free 35.5 34

19.16
 Loosen the clutch locking nut and that on primar y driving gear.

Remove the clutch set.

Remove the clutch collar and its flat washer.
Remove the primar y driving gear.
Disassembly of right crankcase cover（One-piece right cover needn't Remove the driving gear and assemble the semi-round key.
remove and assemble clutch cover）

Drain off the oil

Drain off the coolant
Remove the water pipe
Remove the water pump cover
Remove the impellor of the water pump
Loosen the bolt connects right crankcase cover
Remove the right crankcase cover

Disassembly of clutch

Loosen the bolt A of clutch spring.

Remove the clutch lifting plate, spring C and center case B.
Remove the clutch driving friction plate (with friction material), and driben plate
D (Steel one).

Remove the clutch and driving gear

Remove the clutch pushing rod and remove the pushing plate.

19.17
 Assemble the clutch driving gear

Assemble the semi-round key of driving gear.

Assemble the driving gear.
Assemble clutch flat washer and shaft sleeve.

Check the clutch

Check the driving plate thickness by vernier caliper：

Standard： 2.95～3.05
Maintenance limit： 2.7

Assemble the clutch outer case.

Assemble the lower washer of clutch center case.
。

Check the flatness of driven plate by thickness gauge

Standard： ≤0.1
Maintenance limit：0.2

Check the free height of clutch spring by vernier caliper

Standard： 35.5 Assemble the clutch center case.
Maintenance limit： 34 Assemble clutch locking nut shim(The concave side faces downwards).
Assemble the clutch locking nut (Chamfer side face downwards).
Assembly torque：（70～80）N·m。

Assemble the clutch pushing plate

Assemble the bearing and pushing rod.

Assemble driving gear locking nut shim.
Assemble driving gear locking nut.

19.18
 Note: The gasket need be replaced when assembling the right crankcase cover,
clutch cover, secondar y filter cover and that of water pump.
Note: When assembling the shim of locking nut on clutch and driving gear,
the concave side faces to clutch and the gear.

Assembly of right crankcase cover

Gear box
Assemble positioning pin and new gasket.

Issues need pay attention to

Damage the contacting surface of gear box cover and crankcase body shall be
avoided, and impurity drops into the engine is not allowed.

Disassembly of gear box

Remove the gear indicator switch comp. A.

Remove the assembling bolt B on the cover.
Remove the gear box cover C.

Assemble the right crankcase cover.

Assemble the fastening screw, fasten the bolt on positioning pin hole,
then alternatively fasten other bolts.
Assembling torque：（8～12）N·m。

Remove the gearshift spindle

Remove the assembling screw of gear contact plate.

Remove the gear contact plate。
Remove the gearshift arm comp.
Loosen the assembling screw of check plate.
Remove the check plate comp.
Remove the gearshift drum plate.
Remove the positioning bolt of gearshift arm.

Assemble the clutch cover.

Assemble the secondar y oil filter and its cover.
Assemble the water pump impellor.
Assemble the water pump cover.

19.19
 Assemble the gear box cover.
Assemble the positioning pin of gear box cover.
Assemble the new gasket.
Assemble the gear box cover.
Assemble the gear indicator.

Magneto and electrical starting device

Issues need pay attention to

The disassembly and assembly of magneto in this chapter, remove the

left front cover is enough without removing the engine.

Remove the starting motor

Remove the assembling bot A of the motor.
Remove the starting motor B.

Check the gearshift spindle

Check the damage or distortion on gearshift spindle A, in case distorted, the
alignment is necessar y, in case damaged, replace.
Check the damage or distortion on returning spring B, in case it is, replace.
Check the damage on gearshift arm C, in case it is, replace.
Check the damage on gearshift fork plate, in case it is, replace.

Assemble the check plate (Refer to the picture above)

Assemble the positioning pin of gearshift drum plate.
Assemble the gearshift drum plate.
Assemble the positioning pin of gear contact plate.
Assemble the gear contact plate.
Assemble the gear contact plate screw.
Screw fastening torque：（8～12）N·m.
Assemble the check plate comp.
Assemble the check plate bolt.
Check plate bolt assembling torque：（8～12）N·m

Assemble the gearshift arm (Refer to the picture above)

Assemble the gearshift arm positioning bolt F.
Assembling torque for positioning bolt：（25～30）N·m 。

19.20
Remove the left front cover
Drain off the lubricant in engine.
Remove the assembling bolt of left front cover.
Remove the left front cover.
No damage on contact surface is allowed when
removing the left front cover.

Remove the assembling bolt on gear chamber on left front cover.

Remove the gear chamber cover.
Remove the bigger double gear and flat washer.
Remove the magneto
Remove the stator assembling bolt A.
Remove the assembling screw C on stator pressing wire plate.
Remove the stator B of magneto. 。

Remove the rotor assembling bolt A and the shim B.

Remove the rotor comp. of magneto

Remove the electrical starting gear

Remove the plate shaped gear A and its collar under it.
Remove the smaller double gear B and flat washer. Check the abrasion or damage on bigger and smaller double gear,
in case it is, replace immediately.

19.21
Assemble the electrical starting gear
Assemble the collar A of plate shaped gear
Assemble the plate shaped gear.
Assemble the smaller double gear and flat washer.

Assemble the left front cover

Assemble the positioning pin of left front cover.

Assemble new gasket.
Assemble the left front cover.
Fasten the left front cover assembling bolt.
Fastening torque：（8～12）N·m。

Assemble the magneto

Clean up the greasy dirt in taper hole of rotor and taper surface of crankshaft before
assembling the rotor comp. of magneto
Assemble the rotor fastening bolt and coat its thread with loctite glue.
Fastening torque：（100～120）N·m。

Assemble the staring motor

Assemble the starting motor into the left cover.
Fasten the motor assembling bolt.
Fastening torque：（8～12）N·m。

Assemble stator comp. B and fastening bolt A

Fastening torque：（5～9）N·m。
Assemble the stator wire pressing plate and fasten its bolt.
Fastening torque：（5～9）N·m。

19.22
 Assemble the bigger double gear and its flat washer, upper and lower one each
Noisy Oil leakage
in the gear chamber of left front cover.
1.Bigger end of connecting rod abrasion 1. Too plenty the oil
Assemble new gasket to the gear chamber.
2.Connecting rod distorted 2. Oil abrasion or damage
Assemble the gear chamber cover.
3.Bearing of crankshaft main trunnion abrasion. 3.Crankcase damaged
Fasten the gear chamber bolt.
4.Gear abrasion, seizing up or crack
Fastening torque：（8～12）N·m
5.Bearing abrasion or damage

Break up the crankcase

Remove the counter shaft sleeve A and o-ring B.

Remove the bolt connects crankcase.
Remove the right crankcase body.
Remove the case body positioning pin.
Clean up the seal glue on the end surface without damaging.
Note: Knock the left and right crankcase body by a soft hammer for breaking apart the
case, pr y by screwdriver is not allowed, also knocking the crankshaft

Crankshaft and transmission system

Issues need pay attention to

This chapter introduce the disassembly and assembly of crankshaft and transmission
system, the crankcase need break up when doing this work. Other engine replated parts
need break up before the crankcase.

The works before breaking up the crankcase

Remove the engine and lay it on a clean work bench
Drain off the lubricant
Remove the right crankcase cover
Remove the clutch comp.
Remove the oil pump comp.
Remove the left front cover
Remove the magneto comp.
Remove the electrical starting gear and motor
Remove the gear box cover
Remove the gearshift arm comp.
Remove the check plate comp. and gearshift drum plate
Remove the cylinder head comp.
Remove the cylinder body
Remove the piston comp.
Remove the chain, its guiding plate and tensioning plate

Specification of each part

Items Standard（mm） Repair limit（mm）

Radial gap of bigger end 0.008～0.023 0.07 Remove the transmission system

Gap between bigger end and 0.2～0.4 0.6 Remove the fork shaft A
Remove the fork C.
Thickness of gearshift fork 4.93～5.0 4.83 Remove the gearshift drum B.
Remove the main shaft D and counter shaft E.
Diameter of fork pin 5.9～5.95 5.8

Groove width of fork 5.0～5.18 5.33

Groove width of gearshift fork 6.05～6.15 6.2

Trouble shooting

19.23
 Check and confirm the abrasion or damage on the bearing of crankshaft,
in case it is, replace.

Remove the crankshaft Check the transmission system

Check the flexibility of axial sliding of each gear on main or counter shaft.
Remove the balancing shaft B. Check the abrasion or damage on each gear of main and counter shaft.
Remove the crankshaft. Check the width B of fork groove：
Standard： 5.0～5.18
Repair limit：5.33
Check the thickness A of fork plate
Standard ： 4.93～5.0
Check the crankshaft Repair limit ：4.83

Measure the total gap B between end surfaces of bigger end of connecting
rod and crankshaft by thickness gauge A.

Standard： 0.2～0.4
Repair limit：0.6

Check the pin diameter A of fork

Standard ： 5.9～5.95
Repair limit：5.8

Turn the crankshaft by hand and check its

runout by dial gauge.
Standard ： ≤ 0.03
Repair limit：0.05

Check the groove width B on gearshift drum fork

Standard ： 6.05～6.15
Repair limit ：6.2

19.24
Assemble the crankshaft
Assemble the balancing shaft
Heat the bearing hole of crankshaft in left crankcase to（130～150）℃, the slightly
press the crankshaft into the case. Align the guiding direction by the key first, and press and assemble
Turn the crankshaft to check its flexible turning. the driven gear set onto the balancing shaft; Then align the matching mark B
The right end of crankshaft faces upwards, and drop enough oil into its right oil hole， on driving and driven gear, finally assemble the balancing shaft into the crankcase.
then slowly turn the connecting rod until the oil continue overflow from the both
sides of bigger end.

Coat the turning position and each gear with lubricant.

Coat the crankcase contact surface with seal glue.
Switch the left crankcase body to the right one.
Assemble the transmission system

Assemble both the main and counter shaft

together into the crankcase.

Fasten the crankcase assembling bolt

Fastening torque（8～12）N·m。

Assemble the gearshift drum

Assemble the gearshift fork and insert into the main and counter shaft, and
put the fork pin into the shape line groove.
Pay attention to the mark on fork and no incorrect assembly is allowed.
Align the holes of fork shaft, insert the fork shaft, and turn the main and counter
shaft to check the flexible turning, in case not, the re-assembly of the transmission
system is necessar y.

19.25
 Assemble o-ring B and shaft sleeve A on the counter shaft.
Coat the thread of counter shaft with suitable fastening glue,
and assemble smaller fly wheel, sprocket locking washer, driving
sprocket locking nut by sequence whose fastening torque is （40～50）N·m
and pr y the locking washer at flat position of the nut for locking up.
Assemble the chain, its adjusting plate and tensioning plate
Assemble the piston set
Assemble the cylinder body comp.
Assemble the cylinder head comp.
Assemble the check plate and gearshift drum fork plate
Assemble the gearshift arm comp.
Assemble the gear box cover
Assemble electrical starting gear and motor
Assemble the magneto comp.
Assemble the left front cover
Assemble the oil pump comp.
Assemble the clutch comp.
Assemble the right crankcase cover.
Fill up the lubricant
Failure judgement
Engine hard staring or staring failure
Checking direction
1、Check the fuel reached
carburetor→Didn't→ Already
2、Remove the spark plug and
check the spark→Weak spark or no
spark→ Normal spark
3、Check cylinder pressure→Too
low the pressure→ Normal
4、Start engine gain→ignited by
staring failure→Engine ignition
failure
5、Remove spark plug→Wet→Dr y
6、Re-start the engine
Possible cause
1、Empty fuel tank
2、Fuel lock blocked
3、Fuel tube blocked
4、Floating needle seized up
1、Spark plug damage or dirty
2、Magneto failure
3、Ignition switch failure
4、Sensor failure
5、Ignitor failure
6、Ignition coil failure
7、Wire of high voltage failure
8、Short-cut or cut-off
1、Starting skidding or failure
2、Too narrow the valve gap or no gap
3、Valve guiding rod distorted
4.Poor matched valve and cylinder base
5、Cylinder and piston ring abrasion
6、Poor sealing of cylinder head gasket
7、Poor assembly
8、Wrong valve timing
1、Too widely open the throttle valve
2、Air leakage of inlet tube
3、Wrong ignition timing
1、Too wide the throttle
Weak engine power
Checking direction
1、Fast speed rise from idling to
high speed→No speed change→
Normal speed
2、Steadily raise then engine
rotation→No rotation change→
Normal engine acceleration
3、Check ignition timing→incorrect
timing→ correct timing
4、Check valve gaps→Incorrect
valve gaps→ Correct gaps
5、Check cylinder pressure→Too
low the pressure→ Normal pressure
6、Check the spark plug→Carbon
buildup or incorrect color→ Spark
plug normal
7、Check the oil through view
window→Incorrect oil volume→
Normal oil volume
8、Remove the cylinder head
cover，check valve lubrication→
Abnormal→ Normal
9、Check engine overheating→
Overheated→ Normal
10、Under high speed→Engine
knocking→ Normal
Poor performance when the engine is idling or under low speed
Checking direction
1、Check ignition timing and valve
gaps→Incorrect→Correct
2、Check the air leakage in
carburetor connection→Leak→No
leak
3、Check spark plug runout→Weak
or inter val →Normal
Poor performance when engine is under high speed
Possible cause
1、Clutch skidding
2、Clutch abrasion
1、Poor fuel supply
2、Air filter blocked
3、Air hole on carburetor cap blocked
4、muffler blocked
1、CDI damaged
2、Magneto failure
3、Pulse generator failure
1、Incorrect valve gap adjustment
2、Valve base abrasion
1、Too narrow the valve gap
2、Valve distorted or seized up
3、Valve base abrasion
4、Cylinder or piston ring abrasion
5、Cylinder gasket damaged
6、Incorrect timing
7、Spark plug without assembling in
1、No periodical maintenance
2、Incorrect thermal data
3、Too narrow the gap between spark
1、Too high the oil level
2、Too low the oil level
3、Dirty oil
1、Oil tube blocked
2、Oil pump abnormal working
1、Carbon buildup
2、Fuel of wrong specification
3、Clutch skidding
4、Too rich the mixed gas
5、Too much the oil
1、Piston and cylinder abrasion
2、Carbon buildup in chamber
3、Fuel with wrong specification
4、Ignition timing too much advanced
Possible cause
1、CDI failure
2、Magneto failure
3、Sensor failure
4、Narrow valve gap
1、Carburetor seal ring distorted
2、Carburetor connection drop
3、Seal ring crack
1、Spark plug damage
2、Magneto failure
3、Ignition coil failure
4、CDI failure
5、Sensor failure
6、Ignition switch failure
7、Spark plug cap failure
8、Wrong connection or short-cut
19.26
Checking direction
1、Check ignition timing or valve
gaps→Incorrect→ Correct
2、Break up the carburetor fuel
tube→Fuel flow limited→ Fuel freely
flow
3、Check carburetor→Blocked→
Didn’t block
4、Check the valve timing→
Incorrect→Correct
5、Check flash over of spark plug→
Abnormal→normal
Engine abnormal noise
Checking direction
1、Valve abnormal noise
2、Piston and cylinder knocking
3、Bearing abnormal noise
4、Cam chain abnormal noise
5、Driving and driven gear
Possible cause
1、Magneto failure
2、CDI failure
3、Sensor failure
4、Incorrect valve gap
1、Fuel used up in the tank
2、Breathing hole on fuel cap blocked
3、Fuel passage to carburetor blocked
4、Fuel switch blocked
5、Fuel filtering screen blocked
6、Poor connection of negative tube
1、Float needle block
2、Too low the float level
3、Carburetor jet hole blocked
4、Float seized up
1、Chain and sprocket installed wrong
2、Gear worn out
1、Magneto failure
2、CDI failure
3、Sensor failure
4、Ignition switch failure
5、Ignition coil failure
6、Spark plug cap failure
7、Spark plug damaged
8、Short-cut
Possible cause
1、Too wide the valve gap
2、Valve abrasion
1、Piston and cylinder body abrasion
2、Piston pin and smaller end abrasion
3、Bigger end abrasion
1、Connecting rod bearing damaged
2、Camshaft bearing abrasion.
1、Prolonged chain.
2、Timing sprocket teeth abrasion
3 Tension and guide plate abrasion
4、Wrong adjust of chain tensioner
1、Poor gear maching precision
19.27